Mastering Tolerances

for Machined Parts

General machining tolerances & specific
tolerances guidelines

www.xometry.com
 TABLE OF CONTENTS
3 Introduction
4 Xometry Partner Network
5 Xometry Platform
6 Manufacturing Capabilities
7 When to Use Specific Tolerances
8 General Machining Tolerances
9 Basic Tolerances
10 Clearance & Interference Fit
11 Geometric Dimensioning & Tolerance (GD&T)
12 GD&T Glossary
13 GD&T True Position
14 GD&T Flatness, Parallelism, & Perpendicularity
15 GD&T Concentricity & Profile
16 Warning: Avoid Over-Tolerancing
17 Over-Tolerancing Alternatives
18 Stack-Up
19 CAD Drawing Preparation
20 CAD Drawing Specification
21 Inspection Methods Matter
22 Inspection Report Cheat Sheet

www.xometry.com
2
XOMETRY FOR ENGINEERING
AND SOURCING PROFESSIONALS

Our instant quoting platform and massive

network of machine shops is transforming
custom manufacturing. We make it easy for
all customers — from startups to Fortune
500 companies — to access manufacturing
on demand by providing the most efficient
way to source high-quality parts.

• Automated RFQ
• Expert engineering support team
• Best pricing quality and lead times

www.xometry.com
3
0.625’’
XOMETRY PARTNER NETWORK OF
OVER 3,000+ MACHINE SHOPS &
3D PRINTING BUREAUS

Xometry’s
ffff U.S.-based manufacturing
partners form the backbone of our
cutting-edge manufacturing on demand
platform. Our production-as-a-service
offering leverages an extensive network of
over 3,000 highly-vetted local
manufacturing shops from across the
country including ITAR-qualified, AS9100D,
ISO 9001:2015, ISO 13485, and NADCAP
facilities, with over 13 million combined
hours available.

4 www.xometry.com
Xometry Instant Quoting Engine℠

Xometry’s Proprietary
AI-Powered Manufacturing
Platform

Xometry is tapping into the power of Deep

Learning to effect a step change in how
custom manufacturing gets done. We built
a proprietary platform to enable engineers
and product designers to instantly access
the capacity of a nationwide network of
world-class manufacturing facilities and
receive instant DFM feedback, lead times,
and pricing on their custom manufacturing
jobs.

• Instant pricing and quoting

• Manufacturability analysis
• Dynamic pricing and lead times
• Guaranteed high-quality parts

5 www.xometry.com
XOMETRY
MANUFACTURING
CAPABILITIES CNC Machining Sheet Metal Fabrication Plastic 3D Printing
Combines the latest Xometry offers punching, Plastic 3D Printing is
precision CNC milling laser cutting, waterjet one of the fastest and
Capabilities for all of your and turning processes cutting, stamping, & most cost-efficient
with proprietary bending sheet metal methods available for
custom manufacturing technology services the iterative design,
applications from prototyping, and
production of custom
prototype to production parts

Metal 3D Printing Urethane Casting Injection Molding

Builds parts from ground Produces end-use, rigid or Combines the latest
up, allowing for the flexible plastic parts with injection molding
production of parts with high durability, fast lead processes with
very complex geometries times, and production-lev- proprietary
el quality technology and an
experienced team to
deliver high-quality
parts
www.xometry.com 6
 WHEN TO USE SPECIFIC TOLERANCES

There will be variation between parts

Tolerances help identify what range of

variation is acceptable for the purpose

Tolerances that have a lower range than

General Tolerances should be called out
in a drawing

7 www.xometry.com


GENERAL MACHINING For features of orientation (parrallelism ∥ and perpendicularity ⟂) and form (cylindrical,
TOLERANCES flatness ⏥, circularity ○, and straightness ⏤) apply tolerances as follows:

For features of size (L, W, H, Distance Length (inches) Bilateral Tolerances (+ inches) Angularity degrees
⌀) and location (position, 0-12’’ ± 0.005” ± ½°
concentricity, symmetry):
± 0.005’’ 12-34’’ ± 0.010” ± ½°
24-36’’ ± 0.016” (1/64”) ± 1°
Sharp edges will be
broken and deburred by 36-60’’ ± 0.031” (1/32”) ± 1°
default. Critical edges that
Over 60’’ ± 0.063” (1/16”) ± 1°
must be left sharp should
be noted or specified on a
print.

8 www.xometry.com
BASIC TOLERANCES:
BILARTERAL,
UNILATERAL, AND
LIMIT
What’s the difference?
Bilateral is designer-focused Bilateral Unilateral
Limit is inspector-focused 0.625’’ ± 0.005’’ +0.000’’
0.625’’
-0.010’’

Limit
0.630’’
0.620’’
9 www.xometry.com
CLEARANCE AND
INTERFERENCE FITS

Clearance Interference

• Clearance fits need to be toleranced so: • Interference fits need to be toleranced

Any condition of A is less than any so:
condition of B Any condition of A is more than
• This should not require tools to install any condition of B
(loose to tight) • This requires tools to install (press fit,
shrink fits, etc)

10 www.xometry.com
GEOMETRIC DIMENSIONING &
TOLERANCE (GD&T) EXPLAINED

• GD&T is a symbol-based system of communicating feature-based tolerances

• GD&T uses set DATUMS as references for definining feature tolerances
• Datums are typically planes, axes, or cylinders
• Datums become a “universal reference” between designers,
machinists, and quality assurance

GD&T can call out the counterbore

dimensions, location, and tolerances by
using the DATUM references

11 www.xometry.com
GD&T GLOSSARY
Symbol Description
∠ Angularity
○ Circularity
◎ Concentricity
⌭ Cylindricity
⏥ Flatness
∥ Parallelism
⟂ Perpendicularity
⌖ Position
⌒ Profile (line)
⌓ Profile (surface)
⌰ Run-out (total)
↗ Run-out (circular)
⏤ Straightness
⌯ Symmetry
12 www.xometry.com
GD&T: TRUE POSITION ⌖ ⌖ ⌖
True Position, ⌖, is used typically for hole locations
• It determines how much variance a feature
can have from CAD before it is out-of-spec by
referencing datums
• True position is usually used for sets of holes
• Features are machined in the same setup

These measurements typically require equipment

like comparators or CMM

13 www.xometry.com
GD&T: Flatness, Parallelism,
& Perpendicularity
• Flatness, ⏥: non-datum call out for the acceptable
variation on a plane
• Parallelism, ∥: call out to reference the acceptable
variation of a surface from a parallel datum plane
• Perpendicularity, ⟂: call out to reference the
acceptable variation of a surface from a
perpendicular datum plane

These can typically be measured with hand tools

and gauges

14 www.xometry.com
GD&T: Concentricity
& Profile
• Concentricity, ◎, calls out the acceptable deviation
from a datum axis (coaxiality)
• Profile, ⌒ (line) or ⌓ (surface), calls out the
acceptable deviation of a line or surface feature,
typically with curvature

These measurements typically require equipment

like comparators or CMM

www.xometry.com
15
WARNING: AVOID
OVER-TOLERANCING

• Use your title block to cover general tolerances

• Call out tighter tolerances or GD&T on
purpose-critical features only
• GD&T and very tight tolerances may require CMM,
comparators, or non-manual tools

16 www.xometry.com
OVER-TOLERANCING
ALTERNATIVES
Alternatives to overtolerancing
include the use of slots:

Give ample clearance fits to:

• Thru-features like bolts: counterbores
and countersinks should not be the
concern
• Lip mates should be designed to be
flush on only one face
COTS Dowels and indexed features mitigate
the need for excessive tight tolerances

17 www.xometry.com


BE MINDFUL OF STACK-UP

Stack-up is when parts, typically in their

maximum tolerance condition, do not
assemble properly

• When reviewing an assembly, look at

where parts mate: lips, faces, edges,
boss, etc

• Ensure these features are toleranced in

a way where the part can function in
maximum, minimum, and varied
conditions

18 www.xometry.com

PREPPING YOUR CAD AND DRAWINGS

CAD Best Practices

• Model the part to the nominal (middle) of the
tolerances. This mitigates machine operators mistakenly
cutting out-of-tolerance on the first pass
• Use Hole wizards and other templates to reduce
guesswork on nominals
• Model-based definitions may get lost in conversion:
drawings are still necessary

Drawing Best Practices

• Use the Title Block tolerances to reduce clutter
• Only call out critical tolerances, tight tolerances,
GD&T, and unilateral tolerance

Main takeaway: make sure the drawing and

CAD match

19 www.xometry.com
SPECIFYING TIGHT TOLERANCES WITH
XOMETRY: UPLOAD, SELECT, COUNT,
ATTACH

1. Upload your part and specify material, features,

and finishes

2. Select your tightest tolerances in the drop-down

(e.g., 0.002’’)
• Simplify to bilaterial +/-
• For GD&T, assume that tolerance minus 0.001’’
3. Put in the count (#) of all tolerances below general
4. Attach a reference drawing

20 www.xometry.com
INSPECTION METHODS
MATTER

Machining has a variety of selectable

inspection options, from basic report to CMM
to custom requests

Some GD&T callouts may require CMM to

complete:

⌖ True Position
◎ Concentricity
⌒ Line Profile
⌓ Surface Profile

21 www.xometry.com
INSPECTION REPORT CHEAT-SHEET

Above image taken from the Xometry

quoting platform
Inspection and
www.xometry.com 22
Sampling Plan FAQs
FAQ & Live Engineering Support

After Hours/Anytime: Browse our FAQ at

xometry.com/support

23 www.xometry.com
www.xometry.com