AI-Powered Tolerance Modeling: From Weeks to Minutes

Creating a tolerance simulation model is essential yet time-consuming—manual setup of features, assemblies, tolerances, and measurements often takes days or weeks.

Now, DiTuointegrates AI to fully automate the process, delivering faster, standardized models and dramatically boosting efficiency.

Precision Cooling in Electronic Controllers
As the “brains” of rockets, aircraft, and high-speed trains, electronic controllers must stay cool. Hundreds of motherboard components need to be positioned close enough to the cooling plate for heat transfer—but not so close as to cause interference. Factoring in manufacturing deviations makes this a complex challenge.

While DTAS 3D enables early-stage validation, manually modeling hundreds of components can take 10–15 days.

Solution: AI-Driven Automation
This case shows how DTAS 3D uses AI to automate tolerance modeling—turning weeks of work into minutes.

Part 1: Model Overview

This case analyzes an electrical control box (shown above) with housing, supports, plates, and mounted components. To ensure proper cooling during operation, clearances between components, plates, and housing must stay within 0.7–0.9 mm.

Case Scale:

• Components analyzed: 12 

• Model structure: 16 assemblies, 265 features, 24 measurements, 65 tolerances 

• Manual modeling time: hours to complete

In real applications, control boxes contain hundreds of components—making manual modeling tedious and often taking days or weeks.

AI‑Driven Efficiency:

• This 12‑part model: ~1 minute

• Models with hundreds of parts: 10–20 minutes

Assembly Process Flow

Part tolerances

Measurement target

PART 2 Automatic Modeling Steps

Start Automatic Modeling

Step 1: Select the main parts in the assembly

Step 2: Select the support pillars in the assembly

Step 3: Define the coordinate system

Step 4: Select the measuring piece

Modeling Complete

After the above simple operations, the relevant features, tolerances, assembly, and measurements have been established, and the user can directly submit the calculation.

Calculation results

PART 3 Results Presentation

AI‑Driven Modeling in DTAS 3D

DTAS 3D automates tolerance model creation—transforming manual feature, assembly, tolerance, and measurement setup into an AI‑powered workflow. This reduces modeling time by over 80%, letting engineers focus on innovation.