Tooling Cost

Tooling cost appears as Hard Tooling Cost in the cost taxonomy under Capital Costs.

Tooling cost depends on factors in the following areas:

 Mold Material Costs

 Purchased Mold Component Costs

 Tooling Labor Costs

 Miscellaneous Tooling Costs

Mold Material Costs

Following are material costs whose values are specified in toolshop:

• Core and cavity plate material type and rate

• Ejector box material type and rate

• Actions material type and rate

• EDM carbon

Purchased Mold Component Costs

Costs for the following purchased mold components are listed in the looup table tblPurchasedItems:

• Leader Pins Shoulder Bushings

• Return Pins Shoulder Bushings

• Ejector Guide Pins Bushings

• Locating Rings

• Sprue Bushing

• Stop Pins

• Side Locks

• Socket Head Cap Screws Short

• Socket Head Cap Screws Long

• Support Pillars

• Sleeve Pins

• Limit Switches

• Ejector Pins

• Water Manifolds

• Water Manifold Fittings

• Water Hoses

• Quick Hose Disconnects

• Water Baffles

Standard Mold Base Cost

Standard mold base cost is a component of tooling cost.

Standard Mold Base Cost = (A * Mold Area2 + B * Mold Area + C + Height Multiplier * Part Height) *

Mold Base Material Multiplier * Region Multiplier * Ejector BoxMaterial Multiplier

The standard mold base cost is estimated from a curve fit based on the following:

• Mold area (length times width—see Mold Dimensions)

• Part height (see Part Length, Width, and Height)

A, B, C, and Height Multiplier in the formula above are derived from a curve fit using a large, diverse data set.

The value is adjusted using the following factors:

• Mold material (looked up in tblStdMoldBaseMaterialMultiplier)

• Ejector material (looked up in tblStdMoldBaseEjectorBoxMaterialMultiplier)

• Region (see the tool shop variable regionMultiplier)

Tooling Labor Costs

Labor rates for the following are specified in toolshop:

• Machining:

o CNC machining time and EDM machining time per cavity/core, die block, and action/cam, etc.

o Deep hole or gun drilling time for water cooling lines

• Assembly

• Design:

o 3D CAD modeling, mold flow, etc.

o NC programming time per cavity/core, die blocks, actions/cams, etc.

• Finishing/polishing

• Spotting

• Tryout

• CMM inspection

CNC Machining Versus EDM Burning

Some mold components are created with CNC machining only, some mold components are created with EDM burning only, and some mold components are created with a combination of CNC machining and EDM burning.

The cost model assumes the following:

• Only CNC machining is used to create the following components:

o Mold cavity

o Mold core

• Only EDM Burning is used to create sleeve pins.

• Both CNC machining and EDM burning are used to create the following components:

o Speaker grill inserts

o Rib inserts & insert pockets

o Lifters & lifter pockets

o Slides & slide pockets

Labor Costs for Mold Items Created with CNC Machining

Labor costs for CNC machining are based on CNC setup time and item machining time. Following are the mold items created by CNC machining, together with the factors that contribute to machining time:

Cavity & core machining time is the sum of the following

• Cavity & core volume * time per unit volume * number of cavities

• Part surface area * time per unit area * number of cavities

• Runoff area * time per unit area

• Speaker grill volume * time per unit volume * number of cavities

• Total insert volume * time per unit volume * number of cavities

• Total insert pocket volume * time per unit volume * number of cavities

Actions machining time is the sum of the following:

• Total lifter volume * time per unit volume * number of cavities

• Total slide volume * time per unit volume * number of cavities

Labor Costs for Mold Items Created with EDM Burning

Labor costs for EDM burning are based on electrode design time as well as CNC setup and machining time for electrodes.

Electrode design depends on the number of the following features:

• Grill inserts

• Side cores

• Lifters

• Rib inserts

CNC setup and machining time for the creation of electrodes is determined roughly as follows:

• Setup time is 0.25 hours per electrode. The number of electrodes is the sum of the following:

o Total side cores * number of burns per side core

o Total lifters * number of burns per lifter

o Total inserts * number of burns per insert

o Total sleeve pins * number of burns per sleeve pin

o Total speaker grills * number of burns per speaker grill

• Machining time is 0.003 hours per electrode unit volume. The total electrode volume is determined roughly as follows:

o Slide electrode volume * total side cores * number of burns per side core

o Lifter electrode volume * total lifters * number of burns per lifter

o Insert electrode volume * total inserts * number of burns per insert

o Sleeve pin electrode volume * total sleeve pins * number of burns per sleeve pin

o Speaker grill electrode volume * total speaker grills * number of burns per speaker grill

The cost model assumes one slide for each undercut depth specified by a PSO (for a maximum of 4—see Undercut Depths). The number of lifters, ribs, and grills is specified explicitly by PSOs (see Additional User Inputs).

The cost model assumes the following regarding the number of burns per feature:

• Side cores: 3 burns each

• Lifters: 2 burns each

• Inserts: 3 burns each

• Sleeve pins: 2 burns each

• Speaker grills: 3 burns each

Miscellaneous Tooling Costs

Costs for the following also affect tooling costs:

• Heat treatment (rate specified in toolshop. Multiplied by sum of weights for core plates, cavity plates, inserts, and actions.)

• Plating (Multipliers set for all other plating types in tblToolPlatingMultiplier)

• Stress relief (default rate specified in toolshop)

• Texture (Multipliers set for all other textures in tblTexturingMultiplier)

• Freight (default rate specified in toolshop)

• Markup/profit (default rate specified in toolshop)