3DCS Variation Analyst CAA V5 Based

Tolerance Analysis fully integrated into Dassault Systemes CATIA V5 CAD Software

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The Most Powerful Tolerance Analysis Software

Manufacturers across the globe reduce defects and improve their products with 3DCS software for Tolerance Analysis

OEM's and Suppliers across the globe use 3DCS to improve their product quality while reducing manufacturing costs. As a part of Design for Manufacture and Assembly (DFMA) as well as Model Based Definition (MBD), 3DCS is a powerful tool for simulating both assembly processes and part tolerances together to validate design specifications, improve design through iterative changes and root cause build issues. 


Why Use a CAD Integrated Software?

Integrated CAD tools provide a streamlined approach to analysis that improves adoption, training and process implementation. With the ability to open 3DCS for CATIA V5 in the CAD platform, and utilize PMI, FTA, and CAD characteristics, implementation of 3DCS as a tolerance analysis tool becomes easy to learn and apply. With an integrated modeling approach, 3DCS saves the analysis data in the model files, letting users manage their CAD model in leading PLM systems like Teamcenter, Windchill, Enovia and 3DEXPERIENCE and automatically bring their tolerance analysis along. This answers the challenge of both file management and version control.


The Leading Tolerance Analysis Solution - What is it?

3DCS Variation Analyst CAA V5 Based (3DCS for V5) is an integrated software solution in CATIA V5 that simulates product assembly and part tolerance 3D stack-ups through Monte Carlo Analysis and High-Low-Mean (Sensitivity) Analysis.

truck-fender-fea-color-mapActivated as a workbench in CATIA, 3DCS for V5 simulates part and process variation with three kinds of simulation to provide an understanding of your product's quality. This can be viewed as an estimated percent that will be out of specification, giving you an understanding of your risk, as well as current Ppk, Cpk and a variety of other metrics.

In addition, 3DCS lists the contributing features for every measurement in your model, giving you an understanding on where the variation is coming from, not just what it is. 


Model Assembly Process and Part Tolerances - How does 3DCS work?

ITER_Tokamak3DCS for V5 uses three methods of simulation;

1. Monte Carlo Simulation

2. High-Low-Mean (Sensitivity analysis) 

3. GeoFactor (RSS) Analysis

By accurately modeling the assembly, you can see how both the assembly process and the part tolerances contribute to the product's overall variation.  Together, this creates a virtual prototype that can be used to make decisions about design changes and tooling while reducing non-conformance that leads to scrap and rework. 

How does 3DCS Work? Watch the FREE video series on 3DCS


Gain Greater Insight Into Your Design

The Cost of Quality in PLMSimulating products in a digital environment gives engineers the ability to account for variation in key areas; reducing rework, non-conformance and scrap at final assembly early in the design phase when changes are least expensive.

In addition to this, specifications deemed less critical can be relaxed, increasing tolerances and allowing the use of less expensive manufacturing processes. Creating 3-dimensional tolerance stack-ups let engineers know where to focus when measuring and designing, and the ability to create what-if studies allow them to determine solutions that include both process and part tolerances to keep quality high and costs down. 

The 3DCS technology brought our commitment to product quality and safety by design to an even higher level. The tool not only can quantify our technical decisions but truly helps our IPD teams to numerically and visually discuss spatial dimensional variations and its management early in the design phase.

Daniel C. da Silva, Embraer Tolerance Analysis Team LeaderEmbraer

Validate and Optimize GD&T 

Utilize Embedded GD&T (FT&A)

3DCS for V5 can use FTA and embedded GD&T from your CAD to instantly tolerance your parts. Simulate the build to validate your tolerances, then make adjustments to optimize for cost, quality and control. Push your tolerances back to CAD and update your models. 


  • Build analysis models faster (embedded GD&T is not required for a model)
  • Push button import of CAD GD&T
  • Validate and optimize your GD&T in 3DCS as a test lab, then push back when ready


Determine Design Objectives with Visualization

Reduce the need for prototypes

Create life-like images of your product showing worst case scenarios to determine the visual impact of variation stack-ups. Use these studies to determine maximum and minimum tolerances during design and communicate with engineering. Once engineers have determined the manufacturing tolerances, recreate the studies to see how your actual product will look with worst case tolerance stack-ups. These studies together help you improve the Perceived Quality of your product as well as your build quality. 


  • Determine the impact of variation on the appearance of your product
  • See what worst case scenarios will look like on final product
  • Improve both build and perceived quality of products

Determine Contributors and Make Changes

Find the sources of your variation and simulate your changes to determine impact

Find the source of variation, honing in on either particular part tolerances, or processes. Many times the source of variation is in the assembly process and the solution does not require the changing of tolerances. This can give engineers the ability to improve quality without having to make costly tolerance adjustments. In addition, tolerance and process changes can be made in the model and simulated to find optimal conditions to get the greatest increase in quality at the lowest cost. 


  • Find primary source of variation issues from either tolerances or assembly process
  • Make changes and determine the affect of variation
  • Use iterative changes to create the optimal design for maximum quality and minimum cost

Create Reports and Measurement Plans to Collaborate

Streamline the creation and communication of measurement plans and results

Use reports and measurement plans to communicate results across the organization. Detailed engineering reports communicate with other design teams the inputs and outputs of the model so that the results can be repeated and understood. Management Reports communicate the key outputs to managers to support key decision making. Measurement Plans communicate important areas and particular points to be measured at the plant or CMM room to control variation and watch for out-of-spec and non-conformance conditions. 


  • Quickly communicate detailed inputs and outputs with customers and other teams
  • Share key outputs with managers to support important decision making
  • Create Measurement Plans tied to CAD for the manufacturing plant to use in order to control and monitor variation effectively in production, answering the question, 'Where should we measure?'

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