Tolerance Stack-Up Analyzer
RSS + worst-case for assembly tolerance
📚 Learn more — how it works, FAQ & guide Click to expand
Learn more — how it works, FAQ & guide
Click to expand
Tolerance Stack-Up Analyzer (Worst-Case + RSS)
Mechanical engineering tolerance stack-up: worst-case (additive) and Root-Sum-Square (RSS) analysis side by side. Required for GD&T workflows and assembly tolerance verification.
How to use this tool
- 1
List dimensions + tolerances
One per line: nominal,tolerance.
- 2
Pick analysis method
Worst-case (additive) or RSS (statistical).
- 3
See result
Combined tolerance + risk vs spec.
Frequently Asked Questions
Worst-case vs RSS?
Worst-case sums all tolerances assuming everyone hits worst extreme — very safe but conservative. RSS (Root-Sum-Square) assumes random distribution — closer to reality, smaller stack. Use worst-case for safety-critical, RSS for production.
When does RSS not work?
When parts come from same batch (correlated tolerances), small sample sizes, or when distributions are non-normal. RSS assumes Gaussian + independent.
What's the 6-sigma rule?
For 99.997% yield: design for ±3σ tolerance per dimension. RSS combines these: total stack ±3σ stays within spec.
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100% Privacy. This tool runs entirely in your browser. Your data is never uploaded to any server.