Total Tool Material Labor and Misc Services Cost Calculation
Total Tool Material Labor & Misc Services Cost = Design Cost + Design Cutter Paths + (Material and Labor Cost + Miscellaneous Services) * Number of Tools Required
Design Cost: This is the cost of mold, surfaces, and rib insert design. It is calculated as (Design Mold Cost + Design Surface Cost + Design Rib Insert Cost):
Design Mold Cost: This is calculated as (Design Time Hours * Design Rate):
Design Time Hours: This is calculated as: (Design Time Hrs * Mold Closure Complexity):
Design Time Hrs: aPriori performs a lookup in the cmMoldBaseDesignHours table and returns the Base Design Hrs value for the Mold Base Area in the table that is greater than the Mold Base Area (the product of the Mold Base Size – Length and Mold Base Size – Width setup options).
Mold Closure Complexity: This is a complexity factor applied to mold base considerations based on the Mold Closure Type being used. See Mold Closure Complexity Calculation.
Design Rate: The rate of design as specified in the Digital Factory tool shop under Plastic Molding > Processes > Compression Molding > Tool Shops > Default > Design Rate.
Design Surface Cost: This is the cost of parting line surface design. It is calculated as: (Design Surface Time Hours * Design Rate):
Design Surface Time Hours: This is calculated as: (Design Hours Surface Time Base + Time Per Parting Perimeter * Projected Perimeter + Design Hours Surface Time Vents * Number of Vents) * Mold Closure Complexity:
Time Per Parting Perimeter: This is the scaling factor used to adjust design surface base hours for parting lines and depends on the complexity of the parting lines:
If the Parting Line Parting Type geometric property is FLAT, the factor is specified by the cmPartingLineComplexityMultiplierFlat cost model variable (0.013 in starting point Digital Factories).
If the Parting Line Parting Type geometric property is NON_FLAT, the factor is specified by the cmPartingLineComplexityMultiplierNonFlat cost model variable (0.026 in starting point Digital Factories).
Projected Perimeter: This is the parting line’s Projected Perimeter, extracted from geometry and visible in the Geometric Cost Drivers panel.
Design Hours Surface Time Vents: This is the time required to design mold tool surface for vents. Time is per vent and is specified by the cmDesignHrsSurfaceTimeVents cost model variable (0.125 hours in starting point Digital Factories).
Number of Vents: This is calculated as: ((Cavity Length / Vent Spacing) + (Cavity Width / Vent Spacing)) * 2:
Cavity Length and Cavity Width are the part Length and Width properties, respectively.
Vent Spacing: This is the linear spacing between vents and is specified by the cmVentSpacing cost model variable (76.2 mm in starting point Digital Factories).
Mold Closure Complexity: As described above.
Design Rate: As described above.
Design Rib Insert Cost: This is calculated as: (Total Rib Inserts Design Time Hours * Design Rate):
Total Rib Inserts Design Time Hours: This is the sum of the following calculations:
(cmDesignHrsRibInsertSmall cost model variable (3 hours in starting point Digital Factories) * Number of Small Rib Inserts setup option).
(cmDesignHrsRibInsertMedium cost model variable (5 hours in starting point Digital Factories) * Number of Medium Rib Inserts setup option).
(cmDesignHrsRibInsertLarge cost model variable (10 hours in starting point Digital Factories) * Number of Large Rib Inserts setup option).
Design Rate: As described above.
Design Cutter Paths: This is the cost for cutter path design (CNC programming cost). It is calculated as Design Cutter Path Hours * Design Rate:
Design Cutter Path Hours: This is the time for cutter path design; see Design Cutter Path Hours Calculation.
Design Rate: As described above.
Material and Labor Cost: This is the material and labor cost for the tool. This is calculated as Total Tool Material Cost + Total Tool Labor Cost (see Total Tool Material Cost Calculation and Total Tool Labor Cost Calculation).
Miscellaneous Services: See Miscellaneous Services Calculation.
Number of Tools Required: This is the number of mold tools required, based on the production volume and tool life. This is specified by the Number of Tools setup option.