This paper explores a scaling study on the tolerance analysis on microfeatures. Standard geometric tolerances are used on macro and mesoscale parts and features, but as feature size decreases the effects and challenges of maintaining dimensional tolerances increases. A micro cone array was used as a case study for this paper to examine the error propagation of tool and workpeice uncertainties. The cones were designed to be manufactured using an angled cutting tool with variable feature dimensions being the cone height, cone angle, and the base radius of the cones. The effect of flatness of the workpiece was also taken into consideration. A set of 2D geometric mathematical expressions were developed to express these dimensions. A sensitivity study was performed to determine which variables caused the most change to the nozzle tip diameter. This information was then used to determine the XYZ stage resolutions and flatness requirement to maintain desired tolerances for the part as well as show the nonlinear scaling effects of error propagation for microfeatures.