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Engineering Resource Hub

Tolerance Stack-Up Calculator

Check whether a chain of custom dimensions — or a custom magnet against its mating bore — still fits once tolerances are stacked.

Dimension Chain

Dir. Label Nominal Tol. (±)

Stack-Up Result

Total nominal
Worst-case range
Statistical (RSS) range
Worst-case tolerance (±)
RSS tolerance (±)
Worst-case = sum of all tolerances (guaranteed to cover every part, but pessimistic). RSS (root-sum-square) assumes each dimension's tolerance represents a ±3σ limit on a roughly normal, independent distribution — a common statistical-tolerancing assumption, not a guarantee for any single assembly. Use worst-case for safety-critical or low-volume fits; RSS for high-volume production where a small statistical failure rate is acceptable.