THE COMPLETE GUIDE TO

Designing Tight
Tolerance Parts
Introduction
It’s a scenario common in manufacturing: your
design for CNC machined parts requires tight
tolerances, but communicating those needs to a
manufacturer can be complex. You want the
assembly to fit with precision, but you also want
to keep lead times short and costs down.

At Fictiv, we understand the We condensed our knowledge of

importance of getting machined designing for tight tolerances into
parts made right the first time. We this guide to help you ensure your
believe that quality parts start with designs are manufactured precisely
quality designs — which is why we to your specifications. Read on to
built our digital manufacturing learn the key steps you can take to
platform to capture your precise get high-quality outcomes from
design requirements so nothing your machinists.
gets lost in translation between
quote and machining.

THE COMPLETE GUIDE TO DESIGNING TIGHT TOLERANCE PARTS 1

THE COMPLETE GUIDE TO DESIGNING TIGHT TOLERANCE PARTS

Table of Contents

SECTION 1

03 Determining Your Tolerances

SECTION 2

08 Communicating Clearly with GD&T

SECTION 3

16 Validate Designs with Tolerance Stack-ups

SECTION 4

25 Best Practices for Quality Engineering Drawings

SECTION 5

31 Going from Design to Production

THE COMPLETE GUIDE TO DESIGNING TIGHT TOLERANCE PARTS 2

SECTION 1
DetermIning 

Your Tolerances
Machining tolerance is the amount of permitted variance or dimensional
accuracy of a part. By defining the maximum and minimum dimensional
limit for your part, you define how wide the tolerance can be while
remaining within the part’s required specs.
SECTION 1
Determining Your Tolerances

Before you start setting your tolerances, it’s important to Warpage

remember that while you can theoretically design tight
tolerances all you want, you must contend with the realities When and how warpage from machining or 

of production. We work with machinists and manufacturers heat treating will affect tight tolerance features
around the world, and here’s what our (extensive) experience
says you ought to consider as you create your design: Plastic Temperature Variation
Temperature effects when machining plastics (PEEK
and Ultem are two plastics not prone to temperature
variations)

Post Process
Which post-processes require masking 

to maintain machined tolerances

Tight Tolerance Stock Material

Use tight tolerance stock material whenever possible
to decrease machining cost, lead time, and overall risk

T H E C O M P L E T E G U I D E T O D E S I G N I N G T I G H T T O L E R A N C E PA R T S 4
SECTION 1
Determining Your Tolerances

Warpage PEEK and Ultem Post-Processing

Schematic diagram of the continuous annealing process. Source: ResearchGate

Warpage can be unpredictable and have different PEEK and Ultem are plastics that are able to hold Post-processing can add thickness to parts; tight
effects on each part.
tight tolerances as they are not prone to toleranced features should be masked.
temperature variation.

T H E C O M P L E T E G U I D E T O D E S I G N I N G T I G H T T O L E R A N C E PA R T S 5
SECTION 1
Determining Your Tolerances
Precision Machining Tolerance
It's advisable to consider these during the design phase
because in the end it'll reduce the amount of iterations
you have to make — and production will be better able to
hit all of your requirements the first time around.

Before you specify your part tolerance requirements in

an engineering drawing, it’s a good idea to take a look at
Fictiv’s standard tolerance guidelines first.

i.e - 0.01mm is the thickness of paper

T H E C O M P L E T E G U I D E T O D E S I G N I N G T I G H T T O L E R A N C E PA R T S 6
SECTION 1
Determining Your Tolerances

Bilateral, Unilateral & Limit - 


What’s the Difference?

Bilateral Tolerance: Permits variation above and below basic size and
has equal or unequal amounts of variance. The upper variance is
expressed with a + symbol, lower variance is expressed with a - symbol.

 LIMIT:

.1888

.1870
Unilateral Tolerance: Permits variation above or below basic size and
does not permit variation in both (the size may only deviate in one
direction). The upper variation is expressed with a + symbol, lower
variation is expressed with a - symbol.



Limit Tolerance: Does not use a + or - symbol, shows upper and lower
limits of dimension. Anything between these values is acceptable.


Tighter tolerance requirements are generally needed for mating parts,

flexures, and functional geometries like fan blade profiles. The narrower
the requirements and the more sources of error there are, the more
effort is required to meet the tolerance requirements. Tolerances that
have a tighter range than standard should be called out in your drawing.

T H E C O M P L E T E G U I D E T O D E S I G N I N G T I G H T T O L E R A N C E PA R T S 7
SECTION 2
Communicating
Clearly with GD&T
After determining if your part requirements fit within or outside standard
tolerances, you may need to further illustrate your part requirements.
Geometric Dimensioning and Tolerancing (GD&T) is an important tool 

for communication between designer and machinist.


GD&T is a language of symbols and standards to facilitate

communication between engineers and manufacturers. Engineers 

use GD&T to apply tolerances and dimensions to a geometry and define
what a part should look like in its ideal form. What follows are common
definitions and principles of GD&T you need to know to effectively
communicate your design to the people who produce your parts.
SECTION 2
Communicating Clearly with GD&T
Datum Reference Frame
A datum reference frame is a three-dimensional coordinate system
which defines the geometric dimensions and tolerances of a part.
Without this system, product definition can be unclear. In defining a
part, an engineer identifies the datum features on a part that are most
important to the functional requirements of the design — usually the
features that mount the part in the assembly

A datum can be a point, axis or plane of the ideal par

The actual features on the real, imperfect part are the datum feature
Some tolerances are relative to datum features, so define those
datums first

THE COMPLETE GUIDE TO DESIGNING TIGHT TOLERANCE PARTS 9

SECTION 2
Communicating Clearly with GD&T

Feature Control Frames First section


Geometric symbol identifying the type of
Size of Feature tolerance

Feature control frames show tolerances on Tolerance

2D drawings.
Individual Feature Second section

Tolerance The shape of the tolerance zone (diameter
Shape of
Each feature control frame contains only Geometric Tolerance Zone symbol for a round tolerance zone, otherwise
one message (requirement); if two messages
for a feature are necessary, two feature
Characteristic
3X 9±0.25 Tertiary
Datum
Feature
no symbol for a zone between two lines or
planes).

control frames are required.

0.500 M A B M C This section also includes the size of the

tolerance zone, which is always the total
tolerance

Final sections

Feature Modifier Primary Secondary Datum Feature datum features in order of priority

Datum Datum Modifier

Feature Feature

THE COMPLETE GUIDE TO DESIGNING TIGHT TOLERANCE PARTS 10

SECTION 2
Communicating Clearly with GD&T
GD&T Symbols Form
GD&T symbols are placed in the first compartment of a Straightness
feature control frame and define the type of tolerance Controls the deviation of a line on a surface or an axis within a tolerance zone that is
that is to be applied to the feature.
defined by two parallel lines a distance apart. No datum needed
The characteristics are grouped together into types of
tolerance: form, orientation, location, runout, and
location of derived median points. Flatness
Holds flatness of a plane within a given tolerance zone defined by two parallel planes.
No datum needed.

Circularity (roundness)
Controls deviation from a true circle. The tolerance zone is the space in between two
concentric circles.

Cylindricity
Controls deviation from a cylinder. Similar to circularity, but the tolerance zone is
between two concentric cylinders.

THE COMPLETE GUIDE TO DESIGNING TIGHT TOLERANCE PARTS 11

SECTION 2
Communicating Clearly with GD&T
GD&T Symbols Orientation
GD&T symbols are placed in the first compartment of a
feature control frame and define the type of tolerance
that is to be applied to the feature.
Perpendicularity
Controls perpendicularity between two 90 degree surfaces. A datum feature is required.
The characteristics are grouped together into types of Two parallel planes (both perpendicular to the datum feature) act as the tolerance zone.
tolerance: form, orientation, location, runout, and
location of derived median points.

Parallelism
Controls parallelism between two parallel surfaces. A datum feature is required. 

Two parallel planes (both parallel to the datum feature) act as the tolerance zone.

Angularity
Controls the angle between two surfaces. A datum feature is required. Two parallel
planes (both at the required angle to the datum feature) act as the tolerance zone.

THE COMPLETE GUIDE TO DESIGNING TIGHT TOLERANCE PARTS 12

SECTION 2
Communicating Clearly with GD&T
GD&T Symbols Location
GD&T symbols are placed in the first compartment of a
feature control frame and define the type of tolerance
that is to be applied to the feature.
Position
The characteristics are grouped together into types of Controls how far a feature of size can deviate from where it should be. The acceptable
area is generally defined by a circular or cylindrical tolerance zone.
tolerance: form, orientation, location, runout, and
location of derived median points.

Profile of a Surface
A 3D tolerance zone defines where the surface needs to be located. This can be
applied to curved surfaces.

Profile of a Line
A 2D tolerance zone defines the profile along a 2D cross section of a surface.

THE COMPLETE GUIDE TO DESIGNING TIGHT TOLERANCE PARTS 13

SECTION 2
Communicating Clearly with GD&T
GD&T Symbols Runout
GD&T symbols are placed in the first compartment of a
feature control frame and define the type of tolerance Total Runout
that is to be applied to the feature.
Controls the acceptable variation in a surface when it is rotated 360 degrees around a
The characteristics are grouped together into types of central axis (the datum feature). The tolerance zone is defined by two concentric cylinders.
tolerance: form, orientation, location, runout, and
location of derived median points.

Circular Runout
The 2D version of total runout. Circular runout controls the “wobble” of a 2D cross
section. The tolerance zone is the space between two concentric circles.

THE COMPLETE GUIDE TO DESIGNING TIGHT TOLERANCE PARTS 14

SECTION 2
Communicating Clearly with GD&T
Basic Dimensions Material Condition Modifiers
Basic dimensions are theoretically exact Maximum Material Condition (MMC) and Least
numerical values used to define form, size, Material Condition (LMC) communicate that a
orientation, or location of a part or feature.
tolerance applies to a feature at a particular
Basic dimensions are usually shown on a 
 feature size.



drawing enclosed in a box, but can also be

Maximum Material Condition (MMC)

invoked by referencing a standard or by a 


note on the drawing.
The condition where the feature contains the
maximum material with the stated limits of size. (ex:
Any default tolerances in the title block of a largest pin and/or smallest hole)

drawing do not apply to basic dimensions.

Least Material Condition (LMC)

The condition where the feature contains the least

material within the stated limits of size. (ex: smallest
pin and/or largest hole)

Note about inspection: Some GD&T controls can’t be easily verified with hand metrology tools, which is the standard in quick-turn prototyping. We commonly see the following GD&T control symbols on prototype drawings: flatness, profile of a surface, and
true position applied to centers of holes & bosses.

Standard Fictv practice is to skip inspection of these call-outs, unless a machine shop is specifically instructed to provide an advanced inspection with a CMM inspection report.

THE COMPLETE GUIDE TO DESIGNING TIGHT TOLERANCE PARTS 15

SECTION 3
Validating Designs
with Tolerance
Stack-ups

When reviewing an assembly, you want to ensure features are toleranced

so they function together. “Stack-up” refers to comparing the total part
tolerances to the performance limits to see if the design will work
properly when assembled.
SECTION 3
Validating Designs With Tolerance Stack-Ups
To fully illustrate how to utilize this process and mitigate design issues, we’ve broken down the
tolerance stack-up process into 7 steps (and you can learn more about this process in our webinar:

Process For Tolerance Stack-Ups

01 Define product part 02 Determine The Output 03 Determine what failures happen
interactions and states if this stack is inaccurate
For example, a button not pressed, a button fully For example, a clearance or an interference.
For example, it can’t assemble, the product wears
pressed, wave spring.
Layout which interactions need a tolerance stack. quickly, or there is an overstrain of a spring.

Create interactive maps between subsystems 
 Break down any issues into smaller problems 

to determine what is connected. or subsystems in order to address each
systematically.

Determine any deeper interactions within 


the assembly.

T H E CO M P L E T E G U I D E TO D E S I G N I N G T I G H T TO L E R A N C E PA R T S 17
SECTION 3
Validating Designs With Tolerance Stack-Ups
To fully illustrate how to utilize this process and mitigate design issues, we’ve broken down the
tolerance stack-up process into 7 steps (and you can learn more about this process in our webinar:

Process For Tolerance Stack-Ups

04 Determine what hazardous 05 Determine stack limits 06 Determine Cpk and

situation this creates for the system and calculate stack evaluate against target Cpk
Critical to quality or critical function.
Use RSS (Root Sum Squared), Worst Case Analysis Follow flow chart for further critical dimension analysis

Stack-up ID should help mitigate a design issue or Monte Carlo Simulation. Cpk is a statistical measurement for process capability
identified in the design failure mode and effect Accounts only for the variation within subgroup
analysis (DFMEA). Does not account for any shift and drift between
subgroup
Is sometimes called the “potential capability” because
it reflects the potential of a process to produce parts
within spec.

T HE C OM P LE T E G U I D E T O D E S IGNING T IGH T T OLERAN C E P AR T S 18

SECTION 3
Validating Designs With Tolerance Stack-Ups
Full Tolerance Stack Decision Flow
Start
Yes Yes
CTQ Does the dimension contribute more Can you measure and hold a 1.33 Cpk Add critical dimension based on Cpk table
Is this dimension related to a critical to than 25-35% to the CTQ? for this?
quality (CTQ) or does it mitigate risk?
No No
Risk Consider other method(s) of control with
No critical dimension needed your manufacturing team. If severity is
critical or serious, consider 100% inspection
Is this a 2 dimension stack? 
 No Yes
(note: components should function Can you measure and hold a 1.33 Cpk?
properly when both dimensions are at Add critical dimension based on Cpk table
their min/max). No
Consider other method(s) of control...If
Yes severity is a critical or serious, consider
100% inspections.

Is this dimension related to a critical to Yes Decide for each dimension: is this Yes
quality (CTQ) or does it mitigate risk? practical to measure with a measuring Add critical dimension based on Cpk table
system and to hold a 1.33 Cpk?
No No
No critical dimernsion needed Consider other method(s) of control...If
severity is a critical or serious, consider
100% inspections.
T H E C O M P L E T E G U I D E T O D E S I G N I N G T I G H T T O L E RANC E P ARTS 19
SECTION 3

Validating Designs With Tolerance Stack-Ups

Here’s an example to illustrate these steps. 


Sonny, a portable bidet product, was experiencing

difficulty sliding the fluid canister (dark blue) into 


the main device (light blue). Here’s how they fixed

the problem:

THE COMPLETE GUIDE TO DESIGNING TIGHT TOLERANCE PARTS 20

SECTION 3

Validating Designs With Tolerance Stack-Ups

01 Define interactions and states

Fluid canister must fit into main device.

02 Determine output
The cap (green) is sticking out beyond the sliding
surface of the main canister (grey) body.

03 Determine potential failures

If the probable failure (occured in last 10
products) were to occur in a sold product or on
the production line, the device is useless.

THE COMPLETE GUIDE TO DESIGNING TIGHT TOLERANCE PARTS 21

SECTION 3
Validating Designs With Tolerance Stack-Ups
04 Define interactions and states

To fully control risk, do a calculation and/or a test with the design as-is, to prove
progress forward or do a design change to eliminate the issue

Complete the tolerance stack loop method (table shown below).

T H E CO M P L E T E G U I D E TO D E S I G N I N G T I G H T TO L E R A N C E PA R T S 22
SECTION 3
Validating Designs With Tolerance Stack-Ups

05 Define interactions and states

Setting limits is specific to the direct problem
you are trying to solve or the condition you
have identified with your arrows. You are
looking for a gap and the gap needs to be
greater than 0, such that if it were negative the
cap would not drag on the canister body.

T H E C O M P L E T E G U I D E T O D E S I G N I N G T I G H T T O L E R A N C E PA R T S 23
 SECTION 3
Validating Designs With Tolerance Stack-Ups
The use of tolerance stacks allows designers to take
06 Determine Cpk and evaluate against target Cpk something that seems complicated and use simple
math to calculate and reduce risk of failure. After
a. The lower spec limit is being calculated at 1.58. utilizing these simple equations, Sonny’s designers
This isn’t enough to retire the risk. could make a change (from a nominal clearance of
.25 to .264) to eliminate the error. From there, they
could clearly communicate the tolerance needs for
this part to the manufacturing partner and ensure
the canister’s fit.

Note: You can get more in-depth information on

best practice for Tolerance Stack-Ups and download
a free tolerance stack spreadsheet template here.

b. Repeat this for Cpk of 2 (nominal = 0.3162mm)

T H E C O M P L E T E G U I D E TO D E S I G N I N G T I G H T TO L E R A N C E PA R T S 24
SECTION 4
Best Practices for
Quality Engineering
Drawings

Having settled on GD&T as a communication method, and reviewed

tolerance stack-ups within your design, you’re ready to produce your
drawing. What follows are best practices for creating a drawing that’ll be
clearly understood by your machinist.
SECTION 4

Best Practices for Quality Engineering Drawings

01 Layout Drawing Views

Scale the views so there’s enough space 


for notes and dimensions around the
Add center marks to holes if software 

doesn’t automaticall
Add reference views

THE COMPLETE GUIDE TO DESIGNING TIGHT TOLERANCE PARTS 26

SECTION 4
Best Practices for Quality Engineering Drawings

02 Positional Dimensioning
Capture critical dimensions (e.g. where the part interfaces with another part
Pay attention to both the tolerance you want and the tolerance you’re
actually calling ou
The tolerance is determined by significant digits of the basic dimensio
Identical dimensions don’t need to be called out - use “2X
Using all CAPS on your drawing makes it easier to read and understand.

T H E C O M P L E T E G U I D E T O D E S I G N I N G T I G H T T O L E R A N C E PA R T S 27
SECTION 4
Best Practices for Quality Engineering Drawings

03 Hole Callouts
Dimension the hole diameters, depths and associated tolerance
Include any thread tapping require
Represent identical holes with “4X”
Thru holes are holes that go entirely through the part,
Blind holes have a specified depth, called out with a ↧ symbol.
The depth of countersunk holes is called out, preceded by a ⌴ symbol.
Communicate hole tapping needs with thread size & dept
Thread depth is hard to measure precisely; the depth call-out is always
treated as a minimum.

T H E C O M P L E T E G U I D E T O D E S I G N I N G T I G H T T O L E R A N C E PA R T S 28
SECTION 4
Best Practices for Quality Engineering Drawings

04 Surface Notes
Corresponds to the speed and endmill the CNC
operator will use to cut the particular surfac
The tighter the tolerance, the smoother the surface
finish, and the more expensive

T H E CO M P L E T E G U I D E TO D E S I G N I N G T I G H T TO L E R A N C E PA R T S 29
SECTION 4
Best Practices for Quality Engineering Drawings

05 Manufacturing notes
May include plating instructions or part markin
If an entire assembly is being machined, provide an
assembly drawing or instructio
When hardware installation is required, provide
supplier and part number on drawing

T H E C O M P L E T E G U I D E T O D E S I G N I N G T I G H T T O L E R A N C E PA R T S 30
SECTION 5
Going from Design
to Production

Hopefully this guide has been helpful in bridging the communication gap
between designer and manufacturer when it comes to your tight-
tolerance parts. From the use of GD&T symbols, to risk mitigation and
simplifying your engineering drawing, now you know how to help
machinists deliver the parts you need to your specifications.
SECTION 5
Going From Design to Production
Fictiv is a Digital Manufacturing Ecosystem that can help you get tight tolerance parts machined quickly and accurately. The platform is designed to capture and deliver all of your
precise design specifications with highly vetted machinists so you get reliable high quality parts. Here’s how it works:

1 Upload
It's easy. Just create a free account and drag and drop your 2D and 3D design files. If you don't have a 2D drawing,
you can create and annotate one in seconds with Fictiv.
Finish

Alodine

2 Configure
Anodizing Type 2

Anodizing Type 3
Next, select your material and one or more secondary operations. Our platform provides instant feedback on how
Anodizing Type 3 + PTFE your selections change your cost and lead time.

3 Checkout and Track

Then you checkout and your parts are manufactured, fast. And you get updates every step of the way as your
parts are produced — giving you time back to focus on design instead of sourcing components.

T H E CO M P L E T E G U I D E TO D E S I G N I N G T I G H T TO L E R A N C E PA R T S 32
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