Tolerance analysis of compliant, feature-based sheet metal structures for fixtureless assembly

•A model for tolerance analysis, based on a Monte-Carlo-Simulation combined with FEA, is suitable to predict assembly variations in feature-based sheet metal structures.•This model for tolerance analysis can help to properly design joining fixtures.•When using feature-based fixturing to substitute joining fixtures, dimensional requirements can be met.•Assemblies that are manufactured with feature-based fixturing can compete with those that are manufactured using conventional joining fixtures when it comes to assembly accuracy.•Thus, cost can be reduced and flexibility increased in manufacturing systems.