§ 01 / WHY

Why GD&T over linear ± tolerances

Linear tolerance (±0.05mm on a dimension) specifies how much the dimension can vary. But it doesn't specify how features relate to each other. Two features each held to ±0.05mm can be perfectly in tolerance individually yet not assemble correctly.

Example: two bolt holes, each with ±0.05mm position tolerance independently. Acceptable individually — but if both drift in the same direction, the bolt pattern is offset by 0.1mm. Linear tolerance doesn't constrain the relationship between the holes.

GD&T fixes this by tolerating the position of features relative to datums, not just their dimensions. A position tolerance of Ø0.1mm on each hole (referenced to datum A, B, C) constrains the pair to be within a 0.1mm cylinder — regardless of whether they drift the same or opposite directions.

§ 02 / THE

The 5 most-used GD&T symbols

SymbolNameWhat it controls
FlatnessHow flat a surface is — independent of reference
PerpendicularityHow square a feature is to a datum
ParallelismHow parallel a feature is to a datum
Position (True Position)Where a feature's center must land, relative to datums
CylindricityHow cylindrical a round feature is (round + straight)

These five cover about 90% of real-world GD&T use. Other symbols (concentricity, runout, profile, etc.) exist but are either deprecated, special-case, or overlapping with the main five.

§ 03 / DATUM

Datum system — the foundation of GD&T

Every GD&T callout references datums — the surfaces, axes, or points that define the part's reference frame. A typical datum scheme for a machined bracket:

  • Datum A: the primary mounting face (largest or most functional flat surface)
  • Datum B: an edge perpendicular to A (usually a milled edge)
  • Datum C: another edge perpendicular to both A and B (completing the 3D reference)

Together, A|B|C form a right-angle reference frame. Every other feature is dimensioned relative to this frame. For rotational parts (shafts, cylinders), datum A is often an axis rather than a face.

Key principle: datums should be machined features, not raw-stock surfaces. Datuming from a raw cast surface makes every other dimension ambiguous because the raw surface varies part-to-part.

§ 04 / POSITION

Position tolerance — the workhorse

Position tolerance (⌖) is the single most-used GD&T control. It specifies where a feature's center must land relative to datums.

Example: two M6 holes on a bracket. Drawing callout: ⌖ Ø0.1 A|B|C on each hole. This means the hole axis must fall within a 0.1mm-diameter cylinder centered at the theoretical position, with A, B, C as the reference datums.

Bonus modifier: MMC (Ⓜ) — maximum material condition. When specified as ⌖ Ø0.1 Ⓜ A|B|C, the position tolerance grows when the hole is at maximum material (smallest diameter). For bolt-hole patterns, this gives assembly back the tolerance it needs.

§ 05 / FLATNESS

Flatness and perpendicularity — surface controls

Flatness (⬜) applies to a single surface with no datum reference. Callout ⬜ 0.02 means the surface lies between two parallel planes 0.02mm apart — regardless of orientation or location.

Use flatness on:

  • Sealing surfaces (O-ring grooves, gasket mating)
  • Precision mounting surfaces
  • Reference surfaces before further machining

Perpendicularity (⊥) controls a surface or axis relative to a datum. Callout ⊥ 0.05 A means the controlled feature must be perpendicular to datum A within a 0.05mm zone.

Use perpendicularity on:

  • Bore axes that must be square to a mounting face
  • Walls that must be perpendicular to the base
  • Features that mate with other perpendicular surfaces
§ 06 / COMMON

Common mistakes

Using GD&T on every feature
Every GD&T callout requires inspection — often CMM measurement. Parts with 30 GD&T callouts take 10-20× longer to inspect than parts with 5 strategic callouts. Use GD&T only where relationships matter; use linear tolerances elsewhere.
Datum on rough surface
Datum A must be a clean, machined surface. Datuming from a raw cast or forged surface makes every other dimension ambiguous because the raw surface varies. First operation in machining creates the datum.
Too-tight position tolerance
Position tolerance of Ø0.05mm on a bolt hole is overkill in most cases — bolts have inherent clearance that makes Ø0.2mm position adequate. Tight position tolerance on non-critical features inflates cost without benefit.
Concentricity instead of position
Concentricity is nearly always the wrong choice. It's deprecated in modern ASME Y14.5 in favor of position tolerance for round features. Replace concentricity callouts with position tolerance referenced to the axis.
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