Tolerance Stack Up Calculator -

Pick one critical gap in your current assembly. Build the Excel sheet above. Compare worst-case vs RSS. You’ll be surprised how often your initial tolerances are either too tight (expensive) or too loose (non-functional).

Assign a “+” if the dimension increases the gap/stack, “-” if it decreases. tolerance stack up calculator

Example spreadsheet structure:

If you aren’t calculating it, you’re gambling with your production schedule. In this post, I’ll show you how to build a simple (and why you need more than just worst-case math). What Is Tolerance Stack-Up? Tolerance stack-up is the cumulative effect of individual part tolerances on an assembly’s final dimension (gap, interference, or total length). Pick one critical gap in your current assembly