Tolerance compensation


Manual and automatic. With FLEXITOL®  tolerances are compensated continuously.


Tolerance compensation – production efficiency

The use of FLEXITOL® systems permits greater manufacturing tolerances, thereby allowing for more effective production methods.

FLEXITOL® tolerance compensation systems were developed to compensate tolerances cost-effectively and to prevent warping during assembly. A reliable process flow in series production is ensured in this way. In addition, complex adjustment processes are made more efficient.

This product is made by Böllhoff

Method / principle

Manufacturing processes, based on modular concepts, are a fundamental part of the automotive industry.
Individual components are supplied to the final manufacturer, which merely assembles them. During the development process, it is important to define appropriate tolerances to allow for series production. In this context, the FLEXITOL® automatic tolerance compensation system offers a technically optimised and cost-effective solution.


Nowadays there are many examples of modular manufacturing processes in industry – for the assembly of machine housings, drawer runners, cab linings for utility vehicles or drive units for washing machines, for example.

In the automotive industry too, FLEXITOL® ensures the necessary tolerance compensation, especially in the assembly of headlamps, rear lights, instrument panels, mudguards, door frames or roof ledges.


Product benefits
  • Compensation of even relatively high manufacturing tolerances
  • High functional reliability
  • Access required from one side only
  • Easily integrated into a wide range of applications
  • Quick and easy assembly

Product benefits

There are many good reasons for using our products.

Strength and options.
Point by point.

Compensation of even relatively high manufacturing tolerances

Optimal compensation. Appropriate tolerances for reliable series production.

High end-product quality

The cost-effective technical solution. Reliable function and first-class quality.

Quick and easy assembly

Efficient processes. Short and economical cycle times throughout the production process.

Detailed description


Manual and automatic tolerance compensation system

At present, we distinguish between manual and automatic tolerance compensation systems. The appropriate system depends on the area of use. If a component is to be aligned in a subassembly without the usage of tools, manual solutions should be chosen. If the component clearance has already been established in a previous operation, it makes more sense to use automatic solutions. It is also possible to realise a combination of manual and automatic tolerance compensation systems, of course.


Manual tolerance compensation

This tolerance compensation system is screwed into the receiving component to a defined position. During the joining process, the component tolerances are compensated (zero tolerance at delivery of component). Further alignment is possible during assembly. When the joint is released, the set position is retained.

FLEXITOL® – Manual tolerance compensation

Manual tolerance compensation


Automatic tolerance compensation

Two components are aligned or positioned in relation to one another.
When they are screwed together, the gap between the two components is automatically compensated.
The tolerance compensation system fixes the originally aligned position.
When the joint is released, the system returns to its base position.

FLEXITOL® – Automatic tolerance compensation

Automatic tolerance compensation

Product variants

Every project deserves a tailor-made solution.

Learn more about the product types and find the right variant for your particular application.


This two-piece system is made entirely of metal and can thus withstand high loads.
The minimal space requirement in the joint makes this solution easy to install in an existing space – even retrospectively.



FLEXITOL® Hybrid is a multi-part system intended primarily for use in large series production.
The modular design makes it easy to modify differing base heights and tolerance compensation dimensions.



The FLEXITOL® Plastic consists of an adjustment element and a fastening element made of plastic, and is supplied pre-assembled. This subassembly is screwed into the pilot hole in the receiving component made of plastic.



For so-called "banjo screws", the function of the K' in K' thread is also extremely important. The K' in K' thread cuts its own pilot thread into the existing plastic bore hole.


FLEXITOL® special solutions

Attaching a rear light with a manual tolerance compensation system.


FLEXITOL® special solutions

Attaching the roof rail using a manual and an automatic tolerance compensation system.



Find out more: related downloads.

If you would like to know more, simply download the relevant brochures.

Title Language Version File Download
Systems for stepless tolerance compensation
English 0590/16.02 2088 kB / PDF
English 0590/16.02 2088 kb / PDF
Tolerance compensation system
English 11/2020 152 kB / PDF
English 11/2020 152 kb / PDF

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