Manufacturing Engineering

Tolerance Stackup Simulator

Compare Worst-Case and RSS statistical tolerance analysis for a 3-part assembly in a housing. Sweep housing tolerance, visualize gap clearances, and export analysis data.

Model

3-part assembly

WC + RSS

Mesh

38 pts

Tolerance sweep

Output

CSV

Export ready

Parameters

Fit preset

Housing Nominal100 mm

50150

Housing Tolerance ±0.50 mm

0.12

Part 1 Nominal30 mm

1060

Part 1 Tolerance ±0.20 mm

0.051

Part 2 Nominal40 mm

1060

Part 2 Tolerance ±0.20 mm

0.051

Part 3 Nominal25 mm

1060

Part 3 Tolerance ±0.10 mm

0.051

Housing tolerance sweep

Governing Equations

Worst-Case Stackup

Gap_WC = Gap_nom ± Σ|tol_i|

RSS Statistical Stackup

Gap_RSS = Gap_nom ± √(Σ tol_i²)

Gap Nominal

Gap_nom = Housing - ΣParts = 5.00 mm

WC total tolerance: ±1.000 mm. RSS total tolerance: ±0.583 mm.

All WC gaps positive — no interference predicted at worst case.

Assembly Stack Diagram

Gap Nominal

5.00mm

RSS Max Gap

5.583mm

WC Max Gap

6.000mm

WC Min Gap

4.000mm

Gap Bounds vs Housing Tolerance

Tolerance Sweep Data

Housing Tol (mm)	WC Min Gap (mm)	WC Max Gap (mm)	RSS Min Gap (mm)	RSS Max Gap (mm)
0.10	4.400	5.600	4.684	5.316
0.20	4.300	5.700	4.639	5.361
0.30	4.200	5.800	4.576	5.424
0.40	4.100	5.900	4.500	5.500
0.50	4.000	6.000	4.417	5.583
0.60	3.900	6.100	4.329	5.671
0.70	3.800	6.200	4.238	5.762
0.80	3.700	6.300	4.146	5.854
0.90	3.600	6.400	4.051	5.949
1.00	3.500	6.500	3.956	6.044
1.10	3.400	6.600	3.860	6.140
1.20	3.300	6.700	3.763	6.237
1.30	3.200	6.800	3.666	6.334
1.40	3.100	6.900	3.568	6.432
1.50	3.000	7.000	3.470	6.530
1.60	2.900	7.100	3.372	6.628
1.70	2.800	7.200	3.274	6.726
1.80	2.700	7.300	3.175	6.825
1.90	2.600	7.400	3.076	6.924