Missalignment

Missalignment, usually spelled misalignment, is the condition in which two or more components are not positioned as intended relative to each other. It is a common issue in mechanical, optical, and electrical systems and can also describe misfits between processes or goals in organizational contexts.

In mechanical engineering, shaft misalignment refers to non-coaxial or non-parallel shafts. Types include parallel (offset) misalignment, angular misalignment, and combinations of both. Causes include manufacturing tolerances, improper installation, wear, and thermal expansion. Consequences include increased vibration, noise, bearing wear, seal leakage, reduced efficiency, and premature component failure. Measurement tools such as dial indicators and laser alignment systems help quantify misalignment, while corrections may involve adjusting mounting positions, adding shims, selecting flexible couplings, or realigning supports.

In optical systems, misalignment of lenses, prisms, or mirrors can produce blurred images, reduced brightness, or aberrations. Alignment methods use optical collimators, autocollimators, interferometry, and precision mounts to position elements correctly in relation to one another and to the optical axis.

In electrical and mechanical assemblies, misalignment at interfaces or connectors can cause poor contact, uneven load distribution, or accelerated wear. Across domains, misalignment typically reduces performance, increases maintenance needs, and shortens service life.

Prevention and maintenance focus on designing for appropriate tolerances, performing regular inspections, and applying proper alignment procedures during installation and servicing. See also shaft alignment, optical alignment, and alignment tolerance.