Stack-up is not a drawing problem only

Stack-up failures appear when individually acceptable parts are combined in one assembly chain. Fabrication, fixturing, and weld sequence all influence the final envelope.

Pre-fit risk screening

Screen critical interfaces using worst-case and statistical checks before cutting and machining release.

  • Identify datum-critical interfaces and lock measurement sequence.
  • Use inspection hold points before irreversible welding stages.
  • Define rework allowances in early planning, not after failure.

Manufacturing-friendly tolerancing

Tighten only where function demands it. Over-constraining non-critical features drives cost without improving performance.