Tolerance Stack up Calculator Download : Stackup Analysis

Tolerance Stack-up analysis is a design tool used to analyse and optimize a product assembly by calculating the cumulative effects of part tolerances in an assembly. Therefore it helps in ensuring smooth part assembly. Tolerance stack up calculator is used to calculate worst case and RSS tolerance. We suggest you use this guide to know in detail about tolerance stack up analysis.

Tolerance stack up calculator is used to calculate worst case and RSS tolerance.
Click Here to Download Tolerance Stack Up Calculator
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How to Use Tolerance Stack up Calculator ?

Let’s consider an example of five disks with different tolerance values. We will use this tolerance stackup calculator to calculate maximum and minimum height of the stack using worst case and RSS method.

Here are the steps to be followed to use tolerance stackup calculator:


Write down the description and marking of the dimension in first and second column respectively. This will Help you in identification of dimension in future. For example in this example we marked each disk as Disk 1 / Disk 2 respectively.


In the third row we need to define the stack. In other words, the direction of the dimension. For example if we are adding one dimension in another then stack is positive. Whereas when one dimension is subtracted from another then stack is negative.


Next Step is to write down dimension and upper/lower tolerance values in 4 and 5 columns respectively.

That’s It, Now it’s time to check the results !!!

Result Interpretation

In the calculator result section, you can check the mean value of disk stack, lower & upper limits considering worst case and RSS tolerance stackup method. 

To sum up, Tolerance stack up analysis is a very important part of product design. You can use this calculator for worst case and RSS tolerance stackup analysis.

We will keep updating this tolerance stackup calculator. Please add your comments, suggestions or questions in the comment box.

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