designmr-
For complex parts, simple tolerance stackups usually show that the part won't work when the worst-case tolerances are considered. One should introduce statistical probability. But who can put numbers to that without making some parts and measuring them? I can't count the number of times a stackup tempted me to chuck the design but all other things told me to keep it. None of those designs have come back to bite me. That doesn't mean that just because I drive over the same bridge everyday that it will never collapse!
Tunalover