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Can you assume that +/-5% isn't linearly distributed? If so, the tolerance in practice may likely end up even smaller.



There's a fundamental misunderstanding here.

Tolerance is a specification/contractual value - it's the "maximum allowable error". It's not the error of a specific part, it's the "good enough" value. If you need 100 +/- 5%, any value between 95 and 105 is good enough.

Using two components to maybe cancel out the error as you describe. On average, most of the widgets you make by using 2 resistors instead of one may be closer to nominal, but any total value between 95 and 105 would still be acceptable, since the tolerance is specified at 5%.

To change the tolerance you need to have the engineer(s) change the spec.




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