engineering

Tolerance Stack-Up Calculator

Calculate worst-case and RSS statistical tolerance stack-up for multiple dimensions with bilateral tolerances

Tolerance Stack-Up Calculator

Add dimensions with bilateral tolerances (±). Worst-case = Σtᵢ. Statistical (RSS) = √(Σtᵢ²).

Units:
Name
Nominal (mm)
± Tol (mm)

Stack-Up Results (mm)

Total Nominal
100.0000
Worst-Case ± Tol
±0.1200
RSS ± Tol (1σ)
±0.0707
Worst-Case Range
99.8800 to 100.1200
Total range: 0.2400 mm
RSS Statistical Range
99.9293 to 100.0707
Total range: 0.1414 mm

Worst-case: All tolerances at their extreme simultaneously. Conservative, guarantees fit.

RSS (Root Sum Square): Statistical method assuming tolerances are independent and normally distributed. Approximately 99.73% confidence at ±3σ if each tolerance represents ±3σ.

How to Use This Calculator

1

Enter your input values

Fill in all required input fields for the Tolerance Stack-Up Calculator. Most fields include unit selectors so you can work in your preferred unit system.

2

Review your inputs

Double-check that all values are correct and that you have selected the right units for each field. Incorrect units are the most common source of calculation errors.

3

Read the results

The Tolerance Stack-Up Calculator instantly computes the output and displays results with units. All calculations happen in your browser — no loading time and no data sent to a server.

Formula Reference

Tolerance Stack-Up Calculator Formula

See calculator inputs for the governing equation

Variables: All variables and their units are labeled in the calculator interface above.

When to Use This Calculator

  • •Use the Tolerance Stack-Up Calculator when solving homework or exam problems that require quick numerical verification of your hand calculations.
  • •Use it during the design phase to rapidly iterate on parameters before running detailed finite element simulations.
  • •Use it when reviewing a colleague's calculation or checking a vendor's data sheet for plausibility.
  • •Use it to generate reference data for a technical report or presentation without manual computation.

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