Tolerance Stack-Up Calculator

Stack-up adds the tolerances along a dimension chain to predict the final gap or fit. Worst-case sums every tolerance; the statistical RSS method root-sum-squares them for a realistic spread on volume production.

Formula: Worst case = Σ|tolᵢ|; RSS = √(Σ tolᵢ²)

Worked Example

1. Four parts each ±0.005 in. Worst case = 4 × 0.005 = ±0.020 in.
2. RSS = √(4 × 0.005²) = ±0.010 in — half the worst-case spread.

Related concepts

• True Position
• Tolerance Stack-Up
• Maximum Material Condition
• Datum

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