Miscellaneous Services Cost

The Miscellaneous Services Cost includes the costs of stress relief, heat treating, texturing, plating, freight, duty, and tryouts:

Miscellaneous Services = Misc Cost-Stress Relief + Misc Cost-Heat Treating + Misc Cost-Texturing Budget + Misc Cost-Plating + Misc Cost-Freight + Misc Cost-Duty + Misc Cost-Tryouts

Misc Cost-Stress Relief

If stress relief is included in the routing (see Stress Relief Mold) and a plug is required (see Plug Assist Tooling Required), this is given by the formula: (Stress Relief Rate * (Mold Plate Finished Weight + Plug Finished Weight). If a plug is not required, this is the product of Stress Relief Rate and Mold Plate Finished Weight.

  • Stress Relief Rate is specified in the Digital Factory tool shop.

  • Mold Plate Finished Weight is the product of Mold Plate Finished Volume and the Density of the mold material (specified by the setup option Select Mold Material). For Mold Plate Finished Volume, see Mold Plate Finished Volume.

  • Plug Finished Weight is the product of Plug Finished Volume and the Density of the plug material (specified by the setup option Select Mold Material).

    • Plug Finished Volume is a function of part Projected Area and part Height (extracted from geometry), Plug Ram Volume (the product of Plug Ram Diameter and Plug Ram Length), Plug Size Factor (specified by the cost model variable plugSizeFactor; 0.75 in starting point Digital Factories), and the Number of Parts per Sheet. Plug Ram Length is the height of the pressure box. Plug Ram Diameter is specified by the cost model variable plugRamDiameter (25.4mm in starting point Digital Factories).

Mold Plate Finished Volume

Mold Plate Finished Volume is given by the formula:

Mold Plate Finished Volume = Mold Plate Starting Volume - Mold Plate Volume Removed - Mold Plate Vacuum Channel Volume Removed

  • Mold Plate Starting Volume is the product of Mold Base Size - Length, Mold Base Size - Width, and Mold Plate Size - Height.

  • Mold Plate Volume Removed is the product of part Projected Area, part Height, and Number of Parts per Sheet for a negative Mold Type. Part Projected Area and part Height are extracted from geometry. For a positive Mold Type, it is given by the formula: Mold Plate Starting Volume - Mold Plate Base Volume - ((Mold Base Area - (Part Projected Area * Number of Parts per Sheet)) * Part Height) - (Number of Parts per Sheet * Total Formed Part Volume).

    • Mold Plate Starting Volume, Part Projected Area, Part Height are described above.

    • Mold Plate Base Volume is the product of Mold Base Size - Length, Mold Base Size - Width and whichever is greater: Minimum Mold Plate Thickness or Vacuum Channel Allowance. Minimum Mold Plate Thickness is specified by the cost model variable minMoldPlateThickness (50.8mm in starting point Digital Factories). Vacuum Channel Allowance is the product of Vacuum Channel Allowance Factor and Vacuum Channel Depth. Vacuum Channel Allowance Factor is specified by the cost model variable vacuumChannelAllowanceFactor (4 in starting point Digital Factories). Vacuum Channel Depth is specified by the cost model variable vacuumChannelDepth (5.08mm in starting point Digital Factories).

    • Mold Base Area is the product of Mold Base Size - Length and Mold Base Size - Width.

    • Total Formed Part Volume is the sum of Part Volume (extracted from geometry) and Total Formed Hole Volume. Total Formed Hole Volume is the sum of Formed Hole Volume and Formed Multistep Volume. Formed Hole Volume is the sum of the volumes of all Simple Holes and Complex Holes. Formed Multistep Volume is the sum of the volumes of all Multistep Holes.

  • Mold Plate Vacuum Channel Volume Removed is the sum of Mold Plate Vacuum Channel High Tolerance Volume and Mold Plate Vacuum Channel Low Tolerance Volume.

    • Mold Plate Vacuum Channel High Tolerance Volume is the product of Mold Plate Vacuum Holes Quantity and Vacuum Hole High Tolerance Volume:

      • Mold Plate Vacuum Holes Quantity is the product of Number of Parts per Sheet and Mold Plate Cavity Vacuum Holes Quantity, which is given by the formula: Part Projected Perimeter / Vacuum Hole Spacing. Part Projected Perimeter is extracted from geometry. Vacuum Hole Spacing is specified by the cost model variable vacuumHoleSpacing (38.1mm in starting point Digital Factories).

      • Vacuum Hole High Tolerance Volume is a function of Minimum Mold Plate Thickness (described above) and vacuumHoleHighTolFactor (a cost model variable with a default value of 0.2 in starting point Digital Factories).

    • Mold Plate Vacuum Channel Low Tolerance Volume is given by the formula (Mold Plate Vacuum Holes Quantity * Vacuum Hole Low Tolerance Volume) + Mold Plate Vacuum Channel Volume.

      • Mold Plate Vacuum Holes Quantity is described above.

      • Vacuum Hole Low Tolerance Volume is a function of Minimum Mold Plate Thickness (described above), vacuumHoleHighTolFactor (a cost model variable with a default value of 0.2 in starting point Digital Factories), and vacuumHoleLowTolDiameter (a cost model variable with a default value of 5 in starting point Digital Factories).

      • Mold Plate Vacuum Channel Volume is the product of Number of Parts per Sheet and Mold Plate Cavity Vacuum Channel Volume. Mold Plate Cavity Vacuum Channel Volume is the product of Vacuum Channel Depth, Vacuum Channel Width, and Part Projected Perimeter. Vacuum Channel Depth is specified by the cost model variable vacuumChannelDepth (5.08mm in starting point Digital Factories). Vacuum Channel Width is specified by the cost model variable vacuumHoleLowTolDiameter (5mm in starting point Digital Factories). Part Projected Perimeter is extracted from geometry.

Misc Cost-Heat Treating

If heat treating is included in the routing (see Heat Treating of Mold) and a plug is required (see Plug Assist Tooling Required), this is given by the formula: (Heat Treat Rate * (Mold Plate Finished Weight + Plug Finished Weight)). If a plug is not required, this is the product of Heat Treat Rate and Mold Plate Finished Weight.

  • Heat Treat Rate is specified in the Digital Factory tool shop.

  • Mold Plate Finished Weight and Plug Finished Weight are described in Misc Cost-Stress Relief.

Misc Cost-Texturing Budget

This is the product of Texturing Time, Texturing Overhead Rate, and a Region Multiplier.

  • Texturing Time is a function of the texture specified by the setup option Cavity Texture and the corresponding Mold Tech Standard specified in the lookup table cavityTextures. The calculation is the same as is used for Injection Molding – see ‘Cavity Texture’ in the ‘User Inputs Affecting Tooling Costs’ topic in the Plastic Molding section of the Cost Model Guide.

  • Texturing Overhead Rate is the Machining Rate specified in the Digital Factory tool shop.

  • Region Multiplier is specified in the Digital Factory tool shop.

Misc Cost-Plating

If a plug is required (see Plug Assist Tooling Required), this is given by the formula: (Mold Plate Finished Weight + Plug Finished Weight) * Plating Cost Per Mass * Region Multiplier. If a plug is not required, this is the product of Mold Plate Finished Weight, Plating Cost Per Mass, And Region Multiplier.

  • Mold Plate Finished Weight and Plug Finished Weight are described in Misc Cost-Stress Relief.

  • Plating Cost Per Mass: aPriori performs a lookup in the tblToolCoating table and returns the value of Coating Cost Factor for the Coating Type corresponding to the coating selected in the setup option Plating of the Mold.

  • Region Multiplier is specified in the Digital Factory tool shop.

Misc Cost-Freight

This is the product of Freight Rate and Mold Finished Weight. Freight Rate is specified by the setup option Freight Rate. Mold Finished Weight is the sum of Mold Plate Finished Weight, Water Plate Finished Weight, Plug Finished Weight, and Pressure Box Finished Weight. Import

Pressure Box Finished Volume

Pressure Box Finished Volume is given by the formula:

Pressure Box Finished Volume = Pressure Box Starting Volume - Pressure Box Volume Removed

  • Pressure Box Starting Volume is given by the formula: Pressure Box Base Volume + (2 * Pressure Box Long Sidewall Volume) + (2 * Pressure Box Short Sidewall Volume).

    • Pressure Box Base Volume is the product of Mold Base Size - Length, Mold Base Size - Width, and Minimum Pressure Box Thickness (specified by the cost model variable minPressureBoxThickness; 25.4mm in starting point Digital Factories).

    • Pressure Box Long Sidewall Volume is the product of Mold Base Size - Length, Pressure Box Sidewall Height, and Pressure Box Sidewall Thickness.

      • Pressure Box Sidewall Height is given by the formula: Pressure Box Height - Minimum Pressure Box Thickness. Pressure Box Height is the sum of Part Height, Minimum Pressure Box Head Room, and Minimum Pressure Box Thickness. Minimum Pressure Box Head Room is specified by the cost model variable minPressureBoxHeadRoom (12.7mm in starting point Digital Factories). Minimum Pressure Box Thickness is described above.

      • Pressure Box Sidewall Thickness is whichever is the smallest: minPressureBoxSidewallThickness (a cost model variable; 12.7mm in starting point Digital Factories) or Tool Run Off Margin. Tool Run Off Margin is the sum of Part Spacing Margin and Add Tool Run Off Margin. Part Spacing Margin is given by the formula: (Part Spacing / 2). Add Tool Run Off Margin is toolRunOffMargin - Part Spacing Margin. toolRunOffMargin is a cost model variable (38.1mm in starting point Digital Factories).

    • Pressure Box Short Sidewall Volume is the product of Pressure Box Short Sidewall Length, Pressure Box Sidewall Height, and Pressure Box Sidewall Thickness.

      • Pressure Box Short Sidewall Length is given by the formula: Mold Base Size - Width - (2 * Pressure Box Sidewall Thickness).

      • Pressure Box Sidewall Height, and Pressure Box Sidewall Thickness are described above.

  • Pressure Box Volume Removed is a function of minPressureBoxThickness (a cost model variable with a default value of 25.4mm in starting point Digital Factories) and pressureFeedDiameter (a cost model variable with a default value of 12mm in starting point Digital Factories).

Water Plate Finished Volume

Water Plate Finished Volume is given by the formula:

Water Plate Finished Volume = Water Plate Starting Volume - Water Plate Vacuum Channel Volume Removed - Water Plate Water Lines Volume Removed

  • Water Plate Starting Volume is the product of Mold Base Size - Length, Mold Base Size - Width, and Water Plate Height. Water Plate Height is whichever is the greatest: minWaterPlateThickness (a cost model variable with a default value of 76.2mm in starting point Digital Factories) or (Water Line Diameter Allowance + Vacuum Channel Allowance).

    • Water Line Diameter Allowance is the product of waterLineDiameterAllowanceFactor (a cost model variable; 4 in starting point Digital Factories) and Water Line Diameter.

    • Vacuum Channel Allowance is the product of Vacuum Channel Allowance Factor and Vacuum Channel Depth. Vacuum Channel Allowance Factor is specified by the cost model variable vacuumChannelAllowanceFactor (4 in starting point Digital Factories). Vacuum Channel Depth is specified by the cost model variable vacuumChannelDepth (5.08mm in starting point Digital Factories).

  • Water Plate Vacuum Channel Volume Removed is a function of the number of cavities in widthwise and lengthwise layouts, the lengthwise and widthwise vacuum channel volume of the water plate, and the vacuum channel feed volume of the water plate.

  • Water Plate Water Lines Volume Removed is the product of Water Plate Water Lines Quantity and Water Line Diameter.

    • Water Plate Water Lines Quantity is given by the formula: (Mold Base Size - Length / (Water Line Diameter + waterLineSpacing). waterLineSpacing is a cost model variable with a default value of 76.2mm in starting point Digital Factories.

Misc Cost-Duty

This is the product of Import Duty Rate and Mold Finished Weight. Duty Rate is specified by the setup option Import Duty Rate. Mold Finished Weight is described above for ‘Misc Cost-Freight’.

Misc Cost-Tryouts

This is the product of Tryout Time and Tryout Rate. Tryout Time is the product of Time Per Tryout and Number Of Tryouts (if Texture Depth is less than or equal to 0) or Number Of Tryouts + 1 (if otherwise).

  • Time Per Tryout is specified by the cost model variable timePerTryoutBase (12 hours in starting point Digital Factories)

  • Number Of Tryouts is specified by the cost model variable numTryOutBase (2 in starting point Digital Factories)

  • Texture Depth is specified in the lookup table cavityTextures for the texture specified by the setup option Cavity Texture.

  • Tryout Rate is specified in the Digital Factory tool shop.