ABSTRACT
Worst-case tolerance analysis determines the absolute maximum variation possible for a selected distance or gap. This distance is usually not dimensioned (it may have a reference dimension) and is not directly toleranced. If it were directly toleranced, no study would be necessary, as the limits would already be de¢ned. When performing a tolerance stackup, dimensions, tolerances and other variables are added and subtracted to obtain the total variation of the distance being considered. This method assumes that all dimensions in the tolerance stackup may be at their worst-case maximum or minimum, regardless of the improbability.
