Safety-critical aerospace assemblies are produced under a narrower dimensional margin than conventional industrial systems. At the same time, digital manufacturing, composite structures, and hybrid joining routes increase the number of deviation pathways that can affect fit, load transfer, sealing, and long-term reliability. This article develops an analytical model of Six Sigma dimensional control for emerging aviation technologies. The study examines how recent research links tolerance allocation, metrology, digital twins, deviation-source modeling, and capability assurance in aerospace and adjacent high-precision assembly environments. The source base includes ten recent peer-reviewed studies published between 2022 and 2024. Comparative analysis, source analysis, conceptual synthesis, typologization, and analytical generalization were applied. The analytical section reconstructs a closed-loop control architecture, identifies the most stable implementation sequence, and formulates decision rules for process monitoring and intervention. The proposed framework can be used for early design screening, fixture planning, measurement planning, digital model calibration, and production-stage capability governance in safety-critical assembly programs.
Srinivasrao Balaga (Thu,) studied this question.