Tolerance Analysis
Ensuring your assemblies fit and function within manufacturing variation
Know your assembly works before cutting a single piece of metal.
What This Service
Actually Covers
Manufacturing variation is inevitable. Tolerance analysis predicts whether your assembly will function correctly across the full range of part variation — before production begins. We perform worst-case and statistical (RSS) tolerance stack-up analyses, identify the dimensions driving the most variation, and recommend tolerances that balance fit performance with manufacturing cost.
Expert Engineers
Projects Delivered
Client Satisfaction
Support Available
Everything Included
A detailed breakdown of every capability we bring to this engagement — no hidden scope.
Worst-case (WC) linear tolerance stack-up analysis
Root Sum Squares (RSS) statistical tolerance analysis
Monte Carlo simulation for complex multi-component assemblies
3D tolerance stack-up analysis using SolidWorks Simulation / 3DCS
GD&T datum structure definition and datum flow verification
Sensitivity analysis to identify dominant contributors
Tolerance optimisation recommendations for cost vs. performance
Measurement plan development for first-article inspection
How We Approach
This Service
A clear, structured methodology tailored specifically to this engagement.
Assembly Function Identification
Identify the critical assembly functions (gaps, clearances, alignments) that must be controlled.
Dimension Chain Mapping
Map all contributing dimensions and tolerances in the stack-up chain for each critical function.
WC & RSS Analysis
Perform worst-case and RSS calculations, and run Monte Carlo simulation for complex assemblies.
Optimisation & Reporting
Identify dominant contributors, recommend tolerance adjustments, and deliver the full analysis report.
Ideal For
Mechanical assemblies with tight clearances, mating interfaces, or critical alignment requirements going to production.
What You Receive
Tolerance stack-up analysis report (WC + RSS), sensitivity analysis, GD&T recommendations, and measurement plan.
Often Combined With
These services frequently complement Tolerance Analysis in the same project.
3D Modelling & Assembly
Precise parametric 3D models of components, sub-assemblies, and full products
Explore →Custom Enclosure Design
Purpose-built housings that protect, integrate, and impress
Explore →Manufacturing Drawings (GD&T)
Fully detailed 2D drawings with GD&T that manufacturers can build from without ambiguity
Explore →More Services in
This Category
Explore the other specialised services we offer under Mechanical Design & CAD.
3D Modelling & Assembly
Precise parametric 3D models of components, sub-assemblies, and full products
Custom Enclosure Design
Purpose-built housings that protect, integrate, and impress
Manufacturing Drawings (GD&T)
Fully detailed 2D drawings with GD&T that manufacturers can build from without ambiguity
Product Rendering & Visualisation
Photorealistic renders and animations that communicate your product before it exists
Sheet Metal & CNC Design
Parts designed specifically for sheet metal forming and CNC machining
Ready to Start Your
Tolerance Analysis Project?
Tell us about your project and we'll put together an honest, detailed proposal — no lengthy sales pitch.