Tolerance Stack-Up Calculator

Worst-case and statistical (RSS) tolerance accumulation for a linear dimensional chain of up to 5 contributors.

Dimension 1: nominal (mm)Dimension 1: tolerance ± (mm)Dimension 2: nominal (mm)Dimension 2: tolerance ± (mm)Dimension 3: nominal (mm)Dimension 3: tolerance ± (mm)Dimension 4: nominal (mm), optionalDimension 4: tolerance ± (mm)Dimension 5: nominal (mm), optionalDimension 5: tolerance ± (mm)Calculate

Equations

Nominal stack = Σ nominal dimensions. Worst-case tolerance = Σ |tᵢ|. Statistical (RSS) tolerance = √Σtᵢ².

Assumptions

Linear 1D stack, dimensions correctly signed, RSS assumes independent, normally distributed contributors.

Validation

Confirm datum scheme, GD&T and actual process capability before using RSS for production tolerancing.