In chapter 5 lesson 3, Jake explains how the cutting process affects tolerances, the small but important differences between your CAD model and real-world parts. He breaks down what tolerancing means, where variation comes from, and how it impacts both single parts and assemblies.

Jake begins by defining tolerance as the allowable range a dimension can vary from its nominal value, showing how machine movement, temperature, and setup can all affect part accuracy. He then introduces tolerance stacking, where small variations in multiple features or parts add up, potentially causing alignment issues in assemblies. Using examples, he demonstrates how to properly dimension from a common origin to avoid compounding errors.

He also explains how kerf taper, multiple machining operations, and tabs or workholding features contribute to real-world deviation from perfect CAD geometry. By understanding and designing with these tolerances in mind, you can ensure your parts fit together correctly, even after manufacturing variations occur.

What You’ll Learn:

• What tolerancing is and why it matters in manufacturing
• How real-world factors like machine setup and temperature affect accuracy
• The concept of tolerance stacking and how to avoid it
• How to correctly dimension from a common origin for consistent results
• Why tighter tolerances increase cost and complexity
• How kerf, multiple operations, and workholding influence final part fit
• How to design and dimension parts that assemble correctly every time