Material and Labor - Total Tool Material Cost

This section covers the following topics:

Overview

The Material and Labor Cost includes two elements:

Material and Labor Cost = Total Tool Material Cost + Total Tool Labor Cost

aPriori sums the costs for material and labor costs:

  • Total Tool Material Cost: the total tool material cost for tooling is the sum of the cost of the purchased items for making the tool (‘Material Cost - Purchased Tool Components’) and the cost of the raw materials involved (‘Material Cost -Raw Tool Material’). These costs are described in this section.

  • Total Tool Labor Cost: the total labor cost for tooling is the sum total of: CNC Machining Cost, EDM Machining Cost, Finishing Bench Cost, General Machining Cost, Mold Assembly Cost, Tool Trode Certification CMM Cost, Vacuum Line Machining Cost, and Waterline Drilling Cost. See Total Tool Labor Cost. These costs are described in Material and Labor - Total Tool Labor Cost.

Total Tool Material Cost Formula

Total Tool Material Cost is given by the following formula:

Total Tool Material Cost = Purchased Tool Components Cost + Raw Tool Material Cost

The total tool material cost for tooling is the sum of the cost of the purchased items for making the tool and the cost of the raw materials involved.

Purchased Tool Components Cost

This is the sum of the following components:

Cap Head Screw Long

Cap Head Screw Long is the product of Cap Head Screw Long Quantity and Cap Head Screw Long Unit Cost.

  • Cap Head Screw Long Quantity is the sum of Cap Head Screw Long Mold Base Quantity and Cap Head Screw Long Pressure Box Quantity:

    • Cap Head Screw Long Mold Base Quantity is given by the formula: (Mold Base Perimeter / Cap Head Screw Long Mold Base Spacing):

      • Mold Base Perimeter is given by the formula: 2 * (Mold Base Size - Length + Mold Base Size - Width).

      • Cap Head Screw Long Mold Base Spacing is specified by the cost model variable capHeadScrewLongMoldBaseSpacing (152.4mm in starting point Digital Factories).

    • Cap Head Screw Long Pressure Box Quantity: if pressure forming is required (see Pressure Forming Required), this is given by the formula (Mold Base Perimeter / Cap Head Screw Long Pressure Box Spacing. Otherwise, the value is 0.

      • Mold Base Perimeter is described above.

      • Cap Head Screw Long Pressure Box Spacing is specified by the cost model variable capHeadScrewLongPressureBoxSpacing (304.8mm in starting point Digital Factories).

  • Cap Head Screw Long Unit Cost is specified by the Unit Cost value for Socket Cap Screw Long in the lookup table standardToolingComponents.

Cap Head Screw Short

Cap Head Screw Short is the product of Cap Head Screw Short Quantity and Cap Head Screw Short Unit Cost.

  • Cap Head Screw Short Quantity: if pressure forming is required (see Pressure Forming Required), this is specified by the cost model variable capHeadScrewShortSidewall (8 in starting point Digital Factories). Otherwise, the value is 0.

  • Cap Head Screw Short Unit Cost is specified by the Unit Cost value for Socket Cap Screw Short in the lookup table standardToolingComponents.

Core Pull Pneumatics

Core Pull Pneumatics is the product of Number of Parts per Sheet and core Pull Pneumatics Cost Per Cavity. Pull Pneumatics Cost Per Cavity is the sum total of the following costs:

  • Pneumatic Cylinder Material Cost is the product of Pneumatic Cylinder Unit Cost and Pneumatic Cylinder Quantity:

  • Pneumatic Manifold Material Cost is the product of Pneumatic Manifold Unit Cost and Pneumatic Manifold Quantity:

    • Pneumatic Manifold Unit Cost is specified by the Unit Cost value for Pneumatic Manifold in the lookup table standardToolingComponents.

    • Pneumatic Manifold Quantity is given by the formula: (Pneumatic Cylinder Quantity / Pneumatic Cylinders Per Set) * Pneumatic Manifolds Per Cylinder Set)

      • Pneumatic Cylinder Quantity is described above.

      • Pneumatic Cylinders Per Set is specified by the cost model variable pneumaticCylindersPerSet (5 in starting point Digital Factories).

      • Pneumatic Manifolds Per Cylinder Set is specified by the cost model variable pneumaticManifoldsPerCylinderSet (2 in starting point Digital Factories).

  • Pneumatic Manifold Fitting Material Cost is the product of Pneumatic Manifold Fitting Unit Cost and Pneumatic Manifold Fitting Quantity:

    • Pneumatic Manifold Fitting Unit Cost is specified by the Unit Cost value for Pneumatic Hose Fitting in the lookup table standardToolingComponents.

    • Pneumatic Manifold Fitting Quantity is given by the same formula described above for ‘Pneumatic Manifold Quantity.’

  • Pneumatic Hose Material Cost is the product of Pneumatic Hose Unit Cost and Pneumatic Hose Quantity:

    • Pneumatic Hose Unit Cost is specified by the Unit Cost value for Pneumatic Hose in the lookup table standardToolingComponents.

    • Pneumatic Hose Quantity: see Pneumatic Hose Quantity.

  • Pneumatic Hose Fitting Material Cost is the product of Pneumatic Hose Fitting Unit Cost and Pneumatic Hose Fitting Quantity:

    • Pneumatic Hose Fitting Unit Cost is specified by the Unit Cost value for Pneumatic Hose Fitting in the lookup table standardToolingComponents.

    • Pneumatic Hose Fitting Quantity is the product of Pneumatic Hose Quantity and Pneumatic Hose Fittings Per Hose:

      • Pneumatic Hose Quantity: see Pneumatic Hose Quantity.

      • Pneumatic Hose Fittings Per Hose is specified by the cost model variable pneumaticHoseFittingsPerHose (2 in starting point Digital Factories).

Pneumatic Hose Quantity

Pneumatic Hose Quantity is given by the formula:

(Pneumatic Cylinder Quantity* Pneumatic Hoses Per Cylinder * Pneumatic Hose Unit Length Multiplier)

  • Pneumatic Cylinder Quantity is the sum of Number of Small Core Pulls, Number of Medium Core Pulls, and Number of Large Core Pulls.

  • Pneumatic Hoses Per Cylinder is specified by the cost model variable pneumaticHosesPerCylinder (2 in starting point Digital Factories).

  • Pneumatic Hose Unit Length Multiplier is whichever is the greater of: Mold Base Center To Corner Length or pneumaticHoseUnitLengthMultiplier.

    • Mold Base Center To Corner Length is given by the formula (Mold Base Diagonal / 2).

    • pneumaticHoseUnitLengthMultiplier is a cost model variable with a default value of 0.5 in starting point Digital Factories.

Quick Hose Disconnects

Quick Hose Disconnects is the product of Quick Hose Disconnect Unit Cost and Quick Hose Disconnect Quantity:

  • Quick Hose Disconnect Unit Cost is specified by the Unit Cost value for ‘Quick Hose Disconnect’ in the lookup table standardToolingComponents.

  • Quick Hose Disconnect Quantity is the sum of Quick Hose Disconnect Water Line Quantity, Quick Hose Disconnect Vacuum Line Quantity, and Quick Hose Disconnect Pneumatic Line Quantity:

    • Quick Hose Disconnect Water Line Quantity: see Quick Hose Disconnect Water Line Quantity.

    • Quick Hose Disconnect Vacuum Line Quantity is the product of Vacuum Hoses Per Tool Base and Vacuum Hose Unit Length Multiplier.

      • Vacuum Hoses Per Tool Base is specified by the cost model variable vacuumHosesPerToolBase (1 in starting point Digital Factories).

      • Vacuum Hose Unit Length Multiplier is specified by the cost model variable vacuumHoseUnitLengthMultiplier (0.5 in starting point Digital Factories).

    • Quick Hose Disconnect Pneumatic Line Quantity: see Quick Hose Disconnect Pneumatic Line Quantity.

Quick Hose Disconnect Water Line Quantity

Quick Hose Disconnect Water Line Quantity is given by the formula (Water Manifold Quantity * 2):

  • If Mold Base Area is less than waterManifoldSpacingThresholdSmall, Water Manifold Quantity is specified by the cost model variable waterManifoldsTotalSmall (0 in starting point Digital Factories).

  • If Mold Base Area is less than waterManifoldSpacingThresholdMedium, Water Manifold Quantity is specified by the cost model variable waterManifoldsTotalMedium (2 in starting point Digital Factories).

    • waterManifoldSpacingThresholdMedium is a cost model variable with a default of 1,612,900mm^2 in starting point Digital Factories.

  • In all other scenarios, Water Manifold Quantity is specified by the cost model variable waterManifoldsTotalLarge (4 in starting point Digital Factories).

Quick Hose Disconnect Pneumatic Line Quantity

If core pulls are required (that is, the sum of Number of Small Core Pulls, Number of Medium Core Pulls, and Number of Large Core Pulls is greater than 0), this is specified by the formula: (Pneumatic Cylinder Quantity / Pneumatic Cylinders Per Set) * Pneumatic Manifolds Per Cylinder Set). Otherwise, this is 0.

  • Pneumatic Cylinder Quantity is the sum of Number of Small Core Pulls, Number of Medium Core Pulls, and Number of Large Core Pulls.

  • Pneumatic Cylinders Per Set is specified by the cost model variable pneumaticCylindersPerSet (5 in starting point Digital Factories).

  • Pneumatic Manifolds Per Cylinder Set is specified by the cost model variable pneumaticManifoldsPerCylinderSet (2 in starting point Digital Factories).

Vacuum Hose Fittings

Vacuum Hose Fittings is the product of Vacuum Hose Fitting Unit Cost and Vacuum Hose Fitting Quantity:

  • Hose Fitting Unit Cost is specified by the Unit Cost value for Vacuum Hose Fitting in the lookup table standardToolingComponents.

  • Vacuum Hose Fitting Quantity is the product of Vacuum Hose Quantity and Vacuum Hose Fittings Per Hose:

    • Vacuum Hose Quantity: see Vacuum Hose Quantity.

    • Vacuum Hose Fittings Per Hose is specified by the cost model variable vacuumHoseFittingsPerHose (2 in starting point Digital Factories).

Vacuum Hose Quantity

Vacuum Hose Quantity is the product of Vacuum Hoses Per Tool Base and Vacuum Hose Unit Length Multiplier:

  • Vacuum Hoses Per Tool Base is specified by the cost model variable vacuumHosesPerToolBase (1 in starting point Digital Factories).

  • Vacuum Hose Unit Length Multiplier is whichever if the greater of (Mold Base Diagonal / 2) or vacuumHoseUnitLengthMultiplier:

    • Mold Base Diagonal is calculated as the square root of (Mold Base Size - Length^2 + Mold Base Size - Width^2).

    • vacuumHoseUnitLengthMultiplier is a cost model variable with a default of 0.5 in starting point Digital Factories.

Vacuum Hoses

Vacuum Hoses is the product of Vacuum Hose Unit Cost and Vacuum Hose Quantity:

  • Vacuum Hose Unit Cost is specified by the Unit Cost value for Vacuum Hose in the lookup table standardToolingComponents.

  • Vacuum Hose Quantity: see Vacuum Hose Quantity.

Water Baffles

Water Baffles is the product of Water Baffle Unit Cost and Water Baffle Quantity:

  • Water Baffle Unit Cost is specified by the Unit Cost value for Water Baffle in the lookup table standardToolingComponents.

  • Water Baffle Quantity is given by the formula: (Mold Base Size - Length / Baffle Spacing) * (Mold Base Size - Width / Baffle Spacing) * (Projected Area / Mold Base Area):

    • Baffle Spacing is specified by the cost model variable baffleSpacing (76.2mm in starting point Digital Factories).

    • Projected Area is the product of Parting Line Solid Shadow Area and Number of Parts per Sheet.

      • Parting Line Solid Shadow Area is extracted from geometry.

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

Water Hose Fittings

Water Hose Fittings is the product of Water Hose Fitting Unit Cost and Water Hose Fitting Quantity:

  • Water Hose Fitting Unit Cost is specified by the Unit Cost value for Water Hose Fitting in the lookup table standardToolingComponents.

  • Water Hose Fitting Quantity is the product of Water Hose Quantity and Water Hose Fittings Per Hose:

    • Water Hose Quantity: see Water Hose Quantity.

    • Water Hose Fittings Per Hose is specified by the cost model variable waterHoseFittingsPerHose (2 in starting point Digital Factories).

Water Hose Quantity

If Water Manifold Quantity (see Water Manifold Quantity) is less than or equal to 0, Water Hose Quantity is the product of Water Hose Unit Length Multiplier and waterHosesPerToolBase:

  • Water Hose Unit Length Multiplier is whichever is greater of: (Mold Base Diagonal / 2)or waterHoseUnitLengthMultiplier.

    • Mold Base Diagonal is calculated as the square root of (Mold Base Size - Length^2 + Mold Base Size - Width^2).

    • waterHoseUnitLengthMultiplier is a cost model variable with a default value of 0.5 in starting point Digital Factories.

  • waterHosesPerToolBase is a cost model variable with a default value of 2 in starting point Digital Factories.

Otherwise, Water Hose Quantity is the product of Water Manifold Quantity, Water Hoses Per Manifold, and Water Hose Unit Length Multiplier:

  • Water Manifold Quantity: see Water Manifold Quantity.

  • Water Hoses Per Manifold is specified by the cost model variable waterHosesPerManifold (4 in starting point Digital Factories).

  • Water Hose Unit Length Multiplier is described above.

Water Manifold Quantity

If Mold Base Area is less than waterManifoldSpacingThresholdSmall, Water Manifold Quantity is specified by the cost model variable waterManifoldsTotalSmall (0 in starting point Digital Factories).

If Mold Base Area is less than waterManifoldSpacingThresholdMedium, Water Manifold Quantity is specified by the cost model variable waterManifoldsTotalMedium (2 in starting point Digital Factories).

  • waterManifoldSpacingThresholdMedium is a cost model variable with a default of 1,612,900mm^2 in starting point Digital Factories.

In all other scenarios, Water Manifold Quantity is specified by the cost model variable waterManifoldsTotalLarge (4 in starting point Digital Factories).

Water Hoses

Water Hoses is the product of Water Hose Unit Cost and Water Hose Quantity:

  • Water Hose Unit Cost is specified by the Unit Cost value for Water Hose in the lookup table standardToolingComponents.

  • Water Hose Quantity: see Water Hose Quantity.

Water Manifold Fittings

Water Manifold Fittings is the product of Water Manifold Fitting Unit Cost and Water Manifold Fitting Quantity:

  • Water Manifold Fitting Unit Cost is specified by the Unit Cost value for Water Hose Fitting in the lookup table standardToolingComponents.

  • Water Manifold Fitting Quantity is given by the same formula as Water Manifold Quantity.

Water Manifolds

Water Manifolds is the product of Water Manifold Unit Cost and Water Manifold Quantity:

  • Water Manifold Unit Cost is specified by the Unit Cost value for Water Manifold in the lookup table standardToolingComponents.

  • Water Manifold Quantity: see Water Manifold Quantity.

Raw Tool Material Cost

This is the sum of the following material costs:

Core Pulls

If core pulls are required (that is, the sum of Number of Small Core Pulls, Number of Medium Core Pulls, and Number of Large Core Pulls is greater than 0), this is the product of Total Core Pulls Weight and Core Pull Material. If core pulls are not required, the value is 0.

Total Core Pulls Volume

If Number of Small Core Pulls + Number of Medium Core Pulls + Number of Large Core Pulls is 0, then Total Core Pulls Volume is 0.

If the user has overridden the values of the setup options Number of Small Core Pulls, Number of Medium Core Pulls, and Number of Large Core Pulls), then Total Core Pulls Volume is the sum of (Total Small Standard Core Pull Volume, Total Medium Standard Core Pull Volume, and Total Large Standard Core Pull Volume):

In all other scenarios, Total Core Pulls Volume is the sum of (Total Small Bundled Core Pull Volume, Total Medium Bundled Core Pull Volume, and Total Large Bundled Core Pull Volume):

  • Total Small Bundled Core Pull Volume is the product of Number of Parts per Sheet and the total volume of all extracted small core bundles.

  • Total Medium Bundled Core Pull Volume is the product of Number of Parts per Sheet and the total volume of all extracted medium core bundles.

  • Total Large Bundled Core Pull Volume is the product of Number of Parts per Sheet and the total volume of all extracted large core bundles.

EDM Electrodes

If core pulls are required (that is, the sum of Number of Small Core Pulls, Number of Medium Core Pulls, and Number of Large Core Pulls is greater than 0), this is the sum of EDM Electrode Core Pull Pockets Material Cost and EDM Electrode Core Pull Facing Material Cost. If core pulls are not required, the value is 0.

EDM Electrode Core Pull Pockets Material Cost is the product of EDM Electrode Core Pull Pockets Weight and EDM Electrode Material Cost:

  • EDM Electrode Core Pull Pockets Weight is the product of EDM Electrode Core Pull Pockets Volume and EDM Electrode Density:

  • EDM Electrode Material Cost:

EDM Electrode Core Pull Facing Material Cost is the product of EDM Electrode Core Pull Facing Weight and EDM Electrode Material Cost:

  • EDM Electrode Core Pull Facing Weight is the product of EDM Electrode Core Pull Facing Volume and EDM Electrode Density:

  • EDM Electrode Material Cost is described above.

Mold Plate

Mold Plate is the product of Mold Plate Starting Weight and Mold Plate Material.

Water Plate

Water Plate is the product of Water Plate Starting Weight and Water Plate Material.

  • Water Plate Starting Weight is the product of Water Plate Starting Volume and Water Plate Material Density:

    • Water Plate Starting Volume is the product of Mold Base Size - Length, Mold Base Size - Width, and whichever is the greater of 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 Material Density is specified by the Density of the material specified by the material setup option Select Mold Material.

    • Water Plate Material is specified by the cost of the material specified by the material setup option Select Mold Material.

Plug

If a plug is required (see Plug Assist Tooling Required),this is the product of Plug Starting Volume and Plug Material:

  • Plug Starting Volume is the product of Plug Starting Volume and Plug Material Density:

    • Plug Starting Volume is specified by the formula: Number of Parts per Sheet * ((Part Projected Area * Part Height) + Plug Ram Volume).

      • Part Projected Area and Part Height are extracted from geometry.

      • Plug Ram Volume is the product of Plug Ram Diameter and Plug Ram Length. 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).

    • Plug Material Density is specified by the Density of the material specified by the material setup option Select Mold Material.

  • Plug Material is specified by the cost of the material specified by the material setup option Select Mold Material.

Pressure Box

If a pressure forming is required (see Pressure Forming Required), this is the product of Pressure Box Starting Volume and Pressure Box Material:

  • Pressure Box Starting Volume is the product of Pressure Box Starting Volume and Pressure Box Material Density:

  • Pressure Box Material is specified by the cost of the material specified by the material setup option Select Mold Material.

Pressure Box Starting Volume

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. Part Height is extracted from geometry. 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.