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We report on the importance of considering manufacturing inaccuracies in underwater acoustic projectors by elucidating how small variations affect the response characteristics of a projector array in the presence of mutual-loading effects. A wave-based distributed mechanical model accurately calculates the changes arising from small variations, so rapid changes occurring in the vicinity of the transducer resonance can be simulated. The results showed the effects of mutual loading between projector units and confirmed that the changes can be drastically intensified in the presence of manufacturing inaccuracies. A voltage adjustment method to compensate for these changes is also demonstrated as a solution. This framework could guide the design of projector arrays in sound navigation and ranging (SONAR) systems for a variety of applications and, in particular, may contribute significantly to determining manufacturing tolerances. [ABSTRACT FROM AUTHOR]