Professional tolerance calculator for engineers and designers.
Calculate accurate manufacturing tolerances for 45+ materials including ABS, nylon, polycarbonate, glass filled plastics, silicone, sintering, castings and CNC aluminum/steel.
Always assume worst-case tolerances and aim for a robust design—one that continues to function reliably even when tolerances are as loose as possible.
Based on ISO 2768, DIN 16742, ISO 22068 , ISO 10993 and ISO 8062 standards with automatic material shrinkage compensation.
Get instant tolerance recommendations across injection molding, CNC machining, die casting, and 3D printing processes. Completely free—no login required.
Professional tolerance calculator for engineers and product designers. Calculate accurate manufacturing tolerances for 50+ materials including ABS, nylon, polycarbonate, aluminum, steel across injection molding, CNC machining, die casting, and 3D printing processes. Based on ISO 2768, DIN 16742, and ISO 8062 international standards with automatic material shrinkage compensation for mold design.
Every manufactured part has dimensional variation. No process can produce parts to exact nominal dimensions repeatedly. Understanding and specifying appropriate tolerances is critical for three reasons: parts must fit together (assemblies require mating tolerances), parts must function correctly (performance depends on dimensional accuracy), and cost increases exponentially with tighter tolerances (precision costs money in both manufacturing and inspection).
The fundamental rule of tolerance specification: Always design to the widest tolerance that still meets functional requirements. Unnecessary tight tolerances drive up manufacturing costs, slow production, increase scrap rates, and require expensive measurement equipment. Smart engineers specify tight tolerances only where truly needed for fit, function, or safety—and use standard tolerances everywhere else.
ISO 2768 is the international standard for general tolerances on machined metal parts. When you machine aluminum, steel, or stainless steel on CNC mills and lathes, ISO 2768 defines what tolerances are achievable without special process controls. The standard has four tolerance classes:
For a 45mm CNC machined dimension: Fine tolerance = ±0.05mm, Medium tolerance = ±0.10mm, Coarse tolerance = ±0.30mm. That's a 6x difference between fine and coarse—directly impacting manufacturing cost and inspection requirements.
DIN 16742 is the German standard specifically for injection molded plastic parts. It's widely adopted globally because it accounts for the unique behavior of plastics—material shrinkage during cooling, thermal expansion, moisture absorption, and flow direction effects. Unlike machined metals which start oversized and are cut to dimension, molded plastics start as molten material that shrinks as it cools.
DIN 16742 defines tolerances based on both part dimension and material shrinkage characteristics. High-shrinkage materials like polypropylene (PP) and acetal (POM) have wider tolerances than low-shrinkage materials like polycarbonate (PC) and ABS. Glass-filled plastics dramatically improve dimensional stability—30% glass fiber content can reduce shrinkage by 70% and tighten achievable tolerances by 40-50%.
Material shrinkage examples: ABS shrinks 0.4-0.7%, Polycarbonate shrinks 0.5-0.7%, Nylon 66 shrinks 1.5-2.0%, Polypropylene shrinks 1.5-2.5%, Acetal/POM shrinks 2.0-2.2%. For a 45mm dimension, that's 0.9mm shrinkage for PP vs. 0.27mm for ABS—directly affecting achievable tolerance and required mold cavity compensation.
Injection molds and die cast tools consist of two halves that close together. The line where they meet is the parting line. Any dimension that crosses the parting line faces 75-100% worse tolerance than dimensions entirely within one half. This occurs because of unavoidable factors:
Design strategy to avoid parting line penalty: Orient critical mating features entirely within one mold half. Run critical dimensions parallel to parting line rather than across it. Use mechanical locating features (pins, bosses, registers) rather than relying on parting line dimensions. If you must dimension across the parting line, specify wider tolerances and plan for potential secondary machining operations to bring dimensions back to specification.
When plastic or metal cools from molten state to room temperature, it contracts. The mold cavity must be made larger than the desired final part dimension to compensate for this shrinkage. This calculator automatically computes required mold cavity size using the formula: Mold Cavity Dimension = Nominal Dimension × (1 + Shrinkage Rate).
Example: You want a 45mm dimension in final molded ABS part. ABS shrinkage = 0.5%. Mold cavity must be: 45mm × 1.005 = 45.225mm. When the part cools and shrinks, it will measure your target 45mm dimension. This is critical information for tool makers and mold designers.
Important notes on shrinkage: Actual shrinkage varies with wall thickness (thick sections shrink more), gate location and size (affects packing pressure and cooling rate), packing pressure settings (higher pressure reduces shrinkage), cooling time and rate (rapid cooling can lock in stresses), material grade and lot variation (different suppliers, different batches), and post-mold conditioning (some materials absorb moisture and swell).
For critical dimensions, always consult material supplier datasheets for shrinkage data specific to your grade and processing conditions. Consider mold flow analysis software (Moldflow, Moldex3D) for complex geometries. Run design of experiments (DOE) during mold qualification to optimize processing parameters and achieve target dimensions consistently.
Adding glass fiber reinforcement to plastics dramatically improves dimensional stability and tightens achievable tolerances. Glass-filled grades typically contain 15%, 30%, or 50% glass fiber by weight. The benefits for tolerance control:
Trade-offs to consider: Slightly higher material cost (typically 10-20% more), increased tool wear due to abrasive glass fibers, reduced impact strength (more brittle), potential surface finish issues (fiber show-through), and anisotropic properties (stronger in flow direction). For precision parts where dimensional accuracy is critical, glass-filled grades are almost always worth the trade-offs.
ISO 8062 defines tolerance grades for metal castings including die casting, investment casting, and sand casting. Die casting (high-pressure injection of molten metal into steel dies) produces tighter tolerances than sand casting but not as tight as CNC machining. Common die cast materials include aluminum alloys (lightweight, good strength, excellent surface finish), zinc alloys (tightest tolerances, excellent detail reproduction, lower cost tooling), and magnesium alloys (lightest weight, good strength-to-weight, more expensive).
Die casting tolerances depend on part size, material, wall thickness, and die quality. For a 45mm dimension in aluminum die casting: Fine tolerance ±0.20mm, Standard tolerance ±0.30mm, Coarse tolerance ±0.55mm. Zinc die casting achieves slightly better: ±0.18mm, ±0.25mm, ±0.50mm respectively. Like injection molding, dimensions crossing the die parting line have worse tolerances due to die alignment and wear factors.
3D printing (additive manufacturing) tolerances vary significantly by process technology:
3D printing tolerance considerations: Build orientation affects accuracy (XY plane usually more accurate than Z-axis). Support structure removal can damage surfaces. Post-processing (machining, tumbling, vapor smoothing) can improve tolerances and finish. Thermal stress during build causes warping on large flat surfaces. Always verify critical dimensions after printing and budget for post-machining if needed.
When multiple parts assemble together, individual tolerances add up (stack up) affecting final assembly dimensions. Understanding stackup is critical for ensuring parts fit together reliably without excessive gaps or interference. Two methods for calculating stackup:
Stackup reduction strategies: Minimize number of parts in tolerance chain (fewer parts = less stackup). Use datum features and geometric dimensioning & tolerancing (GD&T) to control critical relationships directly rather than through chains of basic dimensions. Design adjustability into assemblies (slots instead of holes, shims, adjustable fasteners). Specify tighter tolerances only on critical mating features—not every dimension. Consider selective assembly (sort parts into tolerance bands, match tight parts with tight counterparts).
This calculator provides general dimensional (linear) tolerances. For complex parts requiring precise control of form, orientation, location, and runout, use Geometric Dimensioning & Tolerancing (GD&T) per ASME Y14.5 (US standard) or ISO 1101 (international standard). GD&T provides more precise control with larger tolerances than traditional plus/minus dimensioning—reducing cost while improving quality.
GD&T tolerance types: Form controls (flatness, straightness, circularity, cylindricity), Orientation controls (perpendicularity, parallelism, angularity), Location controls (position, concentricity, symmetry), Runout controls (circular runout, total runout), Profile controls (profile of a surface, profile of a line). Each control applies to specific datum references, material conditions, and tolerance zones.
General rule of thumb for relating GD&T to dimensional tolerances: Form tolerances (flatness, straightness) typically 50-60% of dimensional tolerance. Orientation tolerances (perpendicularity, parallelism) typically 60-80% of dimensional tolerance. Location tolerances (position, concentricity) often equal to or slightly larger than dimensional tolerance. These are guidelines—actual geometric tolerances depend on functional requirements and manufacturing capabilities.
Professional drawing practice for tolerance specification:
Manufacturing cost doesn't increase linearly with tolerance tightness—it increases exponentially. Halving tolerance typically doubles or triples manufacturing cost. Understanding this relationship prevents over-specification:
Tolerance-driven cost optimization strategy: Default all dimensions to standard tolerance class (ISO 2768-m for machining, DIN 16742 standard for molding). Identify truly critical dimensions—mating features affecting fit, safety-critical dimensions, features affecting product performance. Specify tighter tolerances only on these critical features. Document why each tight tolerance is necessary (fits bearing, controls alignment, prevents interference). Challenge every tight tolerance during design reviews—can you achieve same function with standard tolerance plus better design (locating features, compliance, adjustment)?
This calculator provides guidance based on industry standards and typical capabilities. However, actual achievable tolerances vary significantly between manufacturers based on equipment age and condition, operator skill level, process control maturity, quality system rigor, and workload/scheduling pressure. Best practice: send your design to 2-3 potential manufacturers early in design phase (before finalizing CAD, definitely before ordering tooling). Ask specifically: "What tolerances can you reliably hold on these features with your equipment and normal process control?" Most manufacturers appreciate early engagement and will provide honest capability assessments.
Red flags indicating manufacturer can't meet your tolerances: Reluctance to commit to specific values, vague responses about "we'll do our best", requesting significantly higher prices without explaining why, suggesting you loosen tolerances without understanding functional requirements, no statistical process control (SPC) or measurement system analysis (MSA) in place, no temperature-controlled inspection area for precision work.
Choosing the right material directly affects achievable tolerances and dimensional stability:
Parts manufactured to tight tolerances can grow outside tolerance in service due to environmental factors:
Design strategies for environmental dimensional stability: Specify material grade with appropriate stabilizers (UV, heat, hydrolysis resistant). Design clearances accounting for worst-case thermal expansion across operating temperature range. Use materials with similar thermal expansion coefficients in assemblies to prevent differential expansion. Allow for moisture-induced dimensional growth in nylon parts through generous clearances or dry-as-molded dimensional specifications. Test prototypes in environmental chambers simulating worst-case conditions before production.
Verifying parts meet tolerance specifications requires appropriate measurement equipment and methods:
Measurement system analysis (MSA) is critical: Verify measurement system variation is small compared to tolerance (Rule of thumb: measurement uncertainty should be less than 10% of tolerance width). Perform gauge R&R studies to separate part variation from measurement variation. Calibrate equipment regularly to traceable standards. Train operators on proper measurement techniques.
Statistical tolerance analysis: Monte Carlo simulation predicts assembly variation based on individual part tolerance distributions. More realistic than worst-case arithmetic stackup.
Tolerance allocation: Distributing total assembly tolerance budget across individual components. Tighten tolerances on inexpensive parts, relax tolerances on expensive parts to optimize total cost while meeting assembly requirements.
Design for Six Sigma (DFSS): Designing products and processes to achieve Six Sigma quality (3.4 defects per million). Requires understanding Cpk and process capability relative to tolerances.
Robust design (Taguchi methods): Designing products insensitive to manufacturing variation. Wide tolerances possible when design is inherently robust to dimensional variation.
Automotive: PPAP (Production Part Approval Process) requires demonstrating process capability Cpk ≥ 1.33 for critical dimensions. Tight statistical control needed even for standard tolerances.
Medical devices: FDA requires risk analysis for dimensional variations affecting patient safety or device performance. Tighter control and 100% inspection often mandated for critical features.
Aerospace: AS9100 quality standard requires statistical process control and measurement system analysis. Tight tolerances with rigorous documentation and traceability for safety-critical parts.
Consumer products: Cost-driven optimization. Wider tolerances acceptable where appearance and basic function aren't affected. Focus tight tolerances only on features visible to consumers or affecting perceived quality.
Commodity Plastics: ABS (Acrylonitrile Butadiene Styrene), PP (Polypropylene), PC (Polycarbonate)
Engineering Plastics: Nylon 6 (PA6), Nylon 66 (PA66), POM/Acetal/Delrin, PBT (Polybutylene Terephthalate)
High-Performance Plastics: PEEK (Polyether Ether Ketone), PSU (Polysulfone), PVDF (Polyvinylidene Fluoride)
Glass-Filled Variants: ABS + 30% Glass Fiber, Nylon 66 + 30% Glass Fiber (PA66-GF30), PBT + 30% Glass Fiber
CNC Machined Metals: Aluminum 6061, Steel, Stainless Steel
Die Cast Metals: Aluminum, Zinc
3D Printing: PLA/ABS (FDM), Standard Resin (SLA), Nylon PA12 (SLS)
This professional tolerance calculator is completely free with no restrictions, no premium features, no required login, and no data collection. It's designed to help engineers, product designers, inventors, and manufacturing professionals quickly determine appropriate tolerances based on material, process, and international standards. The tool runs entirely in your browser—no calculations or data are sent to external servers. Copy your results and use them in your CAD software, engineering drawings, and design documentation.
Tolerance specification methodology is fundamental engineering knowledge refined over decades by standards organizations worldwide. This free tool makes professional-grade tolerance determination accessible to everyone committed to designing manufacturable, cost-effective products that fit together reliably.
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