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Tolerance Stack-Up (TSU) Training

Who Should Attend: Designers and Design Engineers and those trouble shooting production problems who have already taken a fundamentals course in geometric dimensioning and tolerancing in accordance with the ASME Y14.5M-1994 standard. Additionally, a GD&T Applications course is recommended.

The Need: Designers and Design Engineers must be able to determine how robust a design is at the sketch phase. Fit of parts is relatively easy to predict. Shift of parts within an assembly requires an understanding of advanced tolerancing concepts. This knowledge is required to perform manual 2-D and computer assisted 3-D analysis.

Course Description: (16 hours) This advanced training teaches you how to study the cumulative effect of part tolerances in order to reduce product costs. You'll learn how to establish part tolerances, perform 2-D analyses of designs, use geometric tolerances in stack ups, and much more. Numerous assemblies will be studied. A workshop to apply tolerance stack-up analysis techniques to student supplied problems may be included.

Course Outline:

Tolerance Allocation and Analysis

  • Why Do We Need to Do More Tolerance Analysis?
  • When should we do tolerance allocation/analysis?
  • Responsibilities of those performing a tolerance analysis: There are always design alternatives!

Within a Part

  • Exercises

Reality Check

  • Tolerance Stack-Up Analysis Procedure
  • Exercises

The Stack-Up Sizes of Internal and External Features

  • Datum Shift
  • Profile Tolerances
  • Exercises


  • Bring your specific design problems as we will investigate as many as time will allow.

Analysis with Multiple Parts

  • Exercises

Dealing with Datum Variation

  • Flatness
  • Perpendicularity
  • Exercises

Fixed and Floating Feature Assemblies

  • Exercises

Statistical Probability Theory

  • Defects vs Variation
  • RSS and Modified RSS
  • Cp and Cpk
  • Applications to tolerance stack-up analysis
  • Exercises

Self Aligning Features

  • Runout
  • Tilt and Shift
  • Exercises


Global Geometric Tolerancing Fundamentals or equivalent.
Global Geometric Tolerancing Applications recommended.

Additional Information:


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