Quality & Metrology worked example

Tolerance Stackup with feature 1 tolerance of 0.25 mm: a worked example

Push feature 1 tolerance up to 0.25 mm and the picture changes. This example computes every intermediate figure at that operating point. Use it when you need a quick worst-case stack of part tolerances to check a fit, gap, or clearance before a design review.

The inputs for this scenario

  • Feature 1 tolerance: 0.25 mm (raised for this scenario; the documented default is 0.1)
  • Feature 2 tolerance: 0.08 mm (unchanged)
  • Feature 3 tolerance: 0.05 mm (unchanged)
  • Feature 4 tolerance: 0.03 mm (unchanged)

Working through the calculation

  • Applying the documented formula (Worst-case tolerance stackup = feature 1 tolerance + feature 2 tolerance + feature 3 tolerance + feature 4 tolerance) to the inputs above produces each figure below.
  • At this operating point the engine returns 0.41 units for worst-case tolerance stackup, the number this scenario is built around.
  • At this operating point the engine returns 0.25 units for element 1.
  • At this operating point the engine returns 0.08 units for element 2.
  • At this operating point the engine returns 0.08 units for element 3 + 4.

How this compares with the baseline

  • Against the tool's baseline example, where feature 1 tolerance sits at 0.1 mm and the headline result is 0.26 units, this scenario comes in 57.69% above the baseline at 0.41 units.
  • It sums up to four individual feature tolerances into a worst-case dimensional stackup and reports the average tolerance per contributor. The value of this scenario is the size of the gap it exposes: that gap, priced out over a year, is the budget you can justify spending to close it.

Results at a glance

  • Worst-case tolerance stackup: 0.41 units (headline result)
  • Element 1: 0.25 units
  • Element 2: 0.08 units
  • Element 3 + 4: 0.08 units

Run it with your numbers

  • Every input above is editable in the live Tolerance Stackup calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.