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Cost Estimators |
The online cost estimator provides a fast and easy way to estimate the cost of manufacturing your custom part. A complete process plan can be built by first selecting a primary process, such as injection molding, metal casting, or machining, and then adding secondary operations. The cost estimation software requires the user to input some basic part geometry and an integrated glossary provides definitions, images, and estimation tips. Also, several process parameters may be customized, such as material prices, hourly rates, and equipment settings. The total and per-part costs are then instantly calculated for the material cost, production cost, and tooling cost. Registered users can save their cost estimates, add part information (name, description, manufacturer, images, etc.), and share their estimates with colleagues or customers.
Injection molding is the most commonly used manufacturing process for the fabrication of plastic parts. Raw plastic material is melted in an injection molding machine and injected into a mold, where it cools and solidifies into the final part. Injection molding is used to produce thin-walled plastic parts for a wide variety of applications, one of the most common being plastic housings.
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Feature Based Estimate |
Low Vol. Feature Based Estimate |
Standard Estimate |
Tooling Estimate |
Reference Parts |
This feature-based cost estimator is for the injection molding of production quantities (over 10,000 units), where more durable and costly tooling can be used due to its small impact on the per-part cost. The material cost is estimated from the part geometry and uses up-to-date material prices. For the production cost, a compatible injection molding machine is selected from a database of over 50 machines and the cycle time is estimated from the part geometry, material properties, and machine specifications. For the tooling cost, a suitable mold base is selected using standard mold dimensions and mold classes and the required mold machining is estimated from the part geometry and other user specifications. These three costs (material, production, and tooling) are calculated for 4 different cavity arrangements (1, 2, 4, and 8 cavities) and the most cost effective option is provided.
This standard injection molding cost estimator does not require any part geometry, but requires more process parameter inputs to calculate a more accurate estimate. The material cost is estimated from the part and runner volumes, an up-to-date material database with pricing, and customizable process parameters. For the production cost, the cycle time must be specified, as well as the machine rate and labor rates. After adding the mold cost, a detailed cost breakdown is provided for the material, production, and tooling costs.
This feature-based cost estimator calculates the tooling cost for injection molding. Based on the part geometry and mold requirements, such as the number of cavities, a suitable mold base is selected using standard mold dimensions. The required mold machining is estimated for the selected SPI mold class and rapid tooling methods may be chosen for a Class 104 mold.
This feature-based cost estimator is for the injection molding of low volumes (under 10,000 units), where rapid tooling methods (high speed machining of Class 104 molds) are used to create the mold due to the large impact on the per-part cost. The material cost is estimated from the part geometry and uses up-to-date material prices. For the production cost, a compatible injection molding machine is selected from a database of over 50 machines and the cycle time is estimated from the part geometry, material properties, and machine specifications. For the tooling cost, a suitable mold base is selected using standard mold dimensions and the required mold machining is estimated from the part geometry and other user specifications. These three costs (material, production, and tooling) are calculated for 4 different cavity arrangements (1, 2, 4, and 8 cavities) and the most cost effective option is provided.
Injection molding calculators for clamping force, cooling time, and thermal diffusivity.
View sample injection molding parts with completed process plans for a baseline estimate.
Die casting is a manufacturing process that can produce metal parts through the use of reusable molds, called dies. The metal, typically a non-ferrous alloy such as aluminum or zinc, is melted in a furnace and then injected into the dies in the die casting machine, where it rapidly cools and solidifies into the final part. Die casting is used to produce housings, pistons, gears, propellers, bushings, etc.
This feature-based cost estimator is for calculating the material, production, and tooling costs for die casting. The material cost is estimated from the part geometry and uses up-to-date material prices. For the production cost, a compatible die casting machine is selected from a database of 18 hot-chamber and cold-chamber machines and the cycle time is estimated from the part geometry, material properties, and machine specifications. For the tooling cost, a suitable die set is selected using standard die dimensions and the required die machining is estimated from the part geometry and other user specifications. These three costs (material, production, and tooling) are calculated for 4 different cavity arrangements (1, 2, 4, and 8 cavities) and the most cost effective option is provided.
This standard die casting cost estimator does not require any part geometry, but requires more process parameter inputs to calculate a more accurate estimate. The material cost is estimated from the part and runner volumes, an up-to-date material database with pricing, and customizable process parameters. For the production cost, the cycle time must be specified, as well as the machine rate and labor rates. After adding the die cost, a detailed cost breakdown is provided for the material, production, and tooling costs.
This feature-based cost estimator calculates the tooling cost for die casting and the number of dies required based on the approximate tool life. Using the part geometry and other specifications, such as the number of cavities, a suitable die set is selected using standard die dimensions and the required die machining is estimated.
View sample die casting parts with completed process plans for a baseline estimate.
Sand casting, the most widely used casting process, utilizes expendable sand molds to form complex metal parts that can be made of nearly any alloy. The metal alloy is melted in a furnace and then ladled and poured into the cavity of the sand mold, which is formed by a pattern. After the molten metal has cooled and solidified into the final part, the sand mold is broken and the part removed. Sand casting is used to produce both small parts, such as gears, pulleys, and connecting rods, as well as large parts, such as housings and bases for large equipment.
This feature-based cost estimator is for calculating the material, production, and tooling costs for sand casting. The material cost includes the cost of the metal, the mold sand, and any sand cores. These costs are estimated from the part geometry and use up-to-date material prices. The production cost includes the cost of melting the metal, making the molds and cores, pouring the metal, and removing and cleaning the castings. The production and labor rates for these operations are estimated for a mid-size foundry using automated equipment. For the tooling cost, the cost of both the pattern and the core-boxes are estimated in a variety of materials, and the optimal choice is provided. These three costs (material, production, and tooling) are calculated for 4 different cavity arrangements (1, 2, 3, and 4 cavities) and the most cost effective option is provided.
This standard sand casting cost estimator does not require any part geometry, but requires more process parameter inputs to calculate a more accurate estimate. The material cost includes the cost of the metal, the mold sand, and any sand cores. The metal cost is calculated from the part and feed system volumes and an up-to-date material database with pricing. The sand cost is based on the mold and core weights and prices per pound. The production cost includes the cost of melting the metal, making the molds and cores, pouring the metal, and removing and cleaning the castings. The user may specify the mold-making and core-making rates and customize the pricing or labor rates for all tasks. For the tooling cost, the cost of both the pattern and the core-boxes may be entered, as well as the quantity required for each. A detailed cost breakdown is then provided for the material, production, and tooling costs.
View sample sand casting parts with completed process plans for a baseline estimate.
Machining refers to a variety of material removal processes in which a cutting tool removes unwanted material from a workpiece. The two most common machining processes are milling, in which a workpiece feeds into a rotating multi-point tool, and turning, in which a single point cutting tool feeds into a rotating workpiece. In each process, several cutting operations are usually performed in a carefully planned sequence to create the desired part shape. Machined parts are typically cubic or cylindrical in their overall shape, but may include a variety of features such as holes, threads, slots, pockets, flat surfaces, tapered surfaces, and even complex surface contours.
This feature-based cost estimator is for calculating the material, production, and tooling costs for machining using a CNC milling machine or CNC turning machine. The material cost is estimated from the specified workpiece dimensions, material, and several customizable stock parameters. The production cost is calculated by estimating the total machining time and using several equipment parameters, such as setup times and hourly rates. The machining time is estimated from the feature geometry and cutting parameters that are specified for each cutting operation that is added. Values for the cutting speed and feed are based on the selected material, operation, and cutting parameters. Lastly, the tooling cost can be estimated by specifying the tool price and reference tool life for each operation.
Drilling calculators for speed/feed and horsepower.
Milling calculators for speed and feed, horsepower, and step-over distance.
Turning calculators for speed and feed, horsepower, and surface rougness.
View sample machining parts with completed process plans for a baseline estimate.