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Build it right before you build it
Simulate tolerance stack-ups, assembly sequences and GD&T inside your CAD platform. Find dimensional issues at the design stage, before tools are cut.
Dimensional issues found during design are cheaper to fix than problems discovered after tooling or production starts.
3DCS builds digital twins of the assembly process and tolerance stack in 3D, so variation is found before tools are cut.
3DCS integrates with major CAD platforms and supports a closed-loop quality workflow by feeding Metrolog measurement data back into the model to validate manufacturing capability.
Dimensional variation analysis (DVA) predicts how part-to-part variation accumulates through an assembly process. You model how components assemble, quantify where tolerances stack up, and resolve critical risks before tooling.
3DCS creates digital twins that simulate real assembly sequences, including fixturing, welding and thermal effects. That is the difference with classic 1D/2D stack-up tools: the model follows how the product is actually built.
Engineers run variation analysis without leaving their design environment, with tolerances read from the CAD model. 3DCS is available as an integrated solution for major CAD platforms, including CATIA, 3DEXPERIENCE, SOLIDWORKS, PTC CREO and SIEMENS NX, as well as a stand-alone Multi-CAD option.
3DCS Variation Analyst CAA V5 Based runs natively inside CATIA V5-V6, so engineers perform variation analysis without leaving their design environment.
3DCS Variation Analyst for 3DEXPERIENCE is available directly on the 3DEXPERIENCE Platform, keeping analysis within the same collaborative environment engineers already use.
3DCS Variation Analyst for SOLIDWORKS integrates directly into SOLIDWORKS, giving engineers access to variation analysis within their existing design workflow.
3DCS Variation Analyst for PTC CREO runs natively inside PTC CREO, enabling engineers to perform variation analysis without leaving their CAD environment.
3DCS Variation Analyst for SIEMENS NX integrates directly into SIEMENS NX, so variation analysis is performed within the same platform engineers use for design.
3DCS Stand Alone Multi-CAD is a deployment option for teams working across multiple CAD platforms, providing variation analysis capability independent of a single native environment.
Each digital build gives quantified outputs: gap and flush, interference predictions, assembly yield, and statistical metrics.
Import PMI/FTA tolerance specifications directly from CAD and apply ASME Y14.5 or ISO standards. Compare them with actual measurement results instead of assumptions.
Sensitivity analysis ranks the tolerances that drive the most variation, so you tighten only where it pays off and relax the rest.
Import measurement data from the plant and trace root causes through the model, without stopping the line.
A closed-loop workflow: build the model in CAD, run thousands of digital builds, then feed Metrolog measurement data back into the model to check real manufacturing capability against design intent.
Build the 3DCS model inside your CAD. Import PMI/FTA tolerances, define locating schemes and assembly sequences.
Run thousands of Monte Carlo builds. Identify variation contributors, risk areas and sensitivity before a single part is made.
Metrolog measurement data feeds back into the model. Design decisions are validated against actual manufacturing capability.
Engineers across industries use dimensional variation analysis with 3DCS to move from 2D stack-ups to full 3D analyses faster, compressing weeks of manual calculation into days of simulation-driven insight.
“We discovered sensitivities in areas we wouldn’t have expected — well outside our region of interest — that had significant influence on the beam.”
“3DCS allowed us to move from 2D stack-ups to full 3D analyses, our team can now identify issues in a matter of days instead of weeks.“
Our engineers will walk you through a demo tailored to your industry and CAD platform.
3DCS
Simulate assembly processes and analyze tolerances
Review the minimum and recommended system requirements for running 3DCS Variation Analyst.
Check that the tolerance scheme delivers the functional requirement.
See fit and finish results before the first prototype.
Compare locating schemes, fixtures and assembly sequences.
Rank contributors and act on the ones that matter.
Fewer late design changes, fewer parts out of tolerance.
Use plant measurement data to find root causes faster.
Prepare your program, simulate offline with digital twins, run and control your inspection, analyze and correct in real time.
Dimensional variation analysis in 3DCS simulates how part tolerances and assembly processes combine to create variation in a finished assembly. The software runs thousands of digital builds to identify variation contributors, sensitivity, gap and flush conditions, interference risks and assembly yield before production.
3DCS creates a data thread that starts with GD&T and locating schemes defined inside your CAD model, then runs digital builds to predict variation across the assembly. Once parts are manufactured, Metrolog measurement data is fed back into the same model, allowing engineers to compare predicted variation against actual manufacturing capability and validate or adjust design decisions based on real plant-floor evidence, closing the loop between design intent and production reality.
We're closing the loop on quality at IMTS 2026 — Sept 14–19
OUT NOW : Inspection Flow is live. Centralize your metrology data and close the quality loop.