Manufacturing Cost Models

aPriori’s rigorous, physics-based process models address common manufacturing processes including sheet metal fabrication, bar & tube fabrication, welded or mechanical assemblies, plastic molding, sand and die casting, forging, turning and multi-axis machining and a wide variety of heat treatments and surface treatment or finishing operations.

Deterministic routings generate the lowest cost production method from an aPriori baseline Virtual Production Environment (VPE), customer specific VPE, or global supplier VPE. This allows manufacturing and purchasing professionals to explore cost saving production alternatives down to the machine level.

Highlighted Features and Capabilities

  • Process set-up control, including production volume, product life, material selection and tooling considerations
  • Automatic or manual machine selection for individual operations
  • Automatic lowest cost or manual routings supported
  • Make/buy decisions supported through multi-factory / multi-process routings
  • Tool libraries (e.g., end mills, drills, etc.) supported
  • Tooling costs are calculated based on both product design and manufacturing process considerations

Manufacturing Process Groups Supported

All manufacturing processes listed in the column titled “Processes in Baseline Cost Models” are included when a customer orders a Process Group.  All manufacturing processes listed in the column titled “Processes Supported by Service Extensions” are available through configuration of the Baseline Cost Models delivered as part of a Process Group.  Service Extensions are delivered by aPriori’s Professional Services team, and require a separate investment above and beyond the purchase of a license to the Process Group.

We are continuously expanding our library of process models and working closely with our customers to support additional manufacturing methods. If you would like to learn more about our current processes or don’t see the one you are interested in on this list, please contact us.

Process GroupProcesses in Baseline Cost ModelsProcesses Supported by Service Extensions
Sheetmetal ICut-to-Length, Shear, Oxyfuel/Plasma/Laser/Waterjet Cutting, Turret Press, Plasma-Punch, Laser-Punch, Bend Brake, 2- 3- and 4- Roller Bending, DeslagFolding, Straightening, Flame-Cut Beveling, Bump Bending, Ironworker, Laser Etching
Sheetmetal IIProgressive Die, Partial Progressive Die, Stage Tooling, Standard Press, 3D Laser
Bar & Tube FabricationReciprocating/Band/Circular Sawing, Shear, Tube Laser, Punching, Rotary Draw, Compression, Bend Brake, 2- 3- and 4- Roller Bending, End Treatments: Bar Forming, Expansion, Flanging, Flaring, Flattening, Knurling, Notching, Reduction, Slotting
Casting ISand CastingLost Wax Investment Casting
Casting II    Die Casting, Permanent Mold Casting
Plastic MoldingSingle Shot Injection Molding, Structural Foam Molding, Reaction Injection Molding Rubber Molding
Roto/Blow MoldingRotational Molding, Blow Molding
Sheet PlasticThermoforming, Vacuum Forming, Drape Molding
Powder MetalCompaction Pressing, Furnace Sintering
Forging  Closed Die Forging
Rapid PrototypingSLA, SLS, 3D PrintingSLM, DLMS
Machining ICNC 3-axis Milling, CNC 4-axis Milling, CNC 5-axis Milling, Sawing/Cut-to-Length, Gun Drilling, Wire EDM, Drill Press, DeburringVertical & Horizontal Boring, Flow Drill, Lapping
Machining IICNC Turning: 2-axis & 3-axis conventional lathes, 2-axis & 3-axis bar feed lathes, Mill-Turn, Deep Bore/ Trepanning, Lathe Roughing (on castings), Lathe Finishing, Single Point Threading, Single Plunge Grooving, Multi-Plunge Grooving, Pinch TurningGraphite Milling, Swiss Lathe, Fine Thread Making
Machining IIIOD Grinding, ID Grinding, Surface Grinding, Single Index Milling, Rotor GrindingHoning, Polishing, Jitterbug Sanding
Gear MakingHobbing, Shaping, Broaching, Rolling, Bevel Gear Cutting, Shaving, Profile Grinding, Threaded Wheel Grinding
Wire Harness ManufacturingWire/Bundle/Conduit Prep (Cut & Strip), Wire Termination (Wire Marking, Manual/Machine Crimp, Solder, Tin, Heat Shrink), Connector Assembly, Splice (Ultrasonic, Butt, Insulation Displacement), Branch Covering, Braid, Harness Layout (Formboard Setup/Test, Wire Layout, Branch Layout, Twist, Labeling (Heat Shrink Label, Wrap-Around Label), Testing (Pull Test, Continuity Test, Hipot Test)
Assembly WeldingWeld Preparation, Manual MIG Welding, Manual Spot Welding, Robotic MIG Welding, Robotic Spot Welding, Weld Cleanup, Welding on PartsTIG Welding, Resistance, Ultrasonic and Friction Welding, Laser Welding, Brazing, Soldering, Electro-Beam Welding, Sub-Arc, Multi-Cell Robotic Welding, Two-Wire MIG Welding
Mechanical AssemblyManual Screw, Power Screw, Press Fit, Snap Fit, Rivet, Tab Bend, Nut InsertAdhesives, Helicoil Insertion , Bonding, Grease Packing, Wire Routing; Most Mechanical Assembly Procedures
Surface TreatmentShot Blast, Degreasing, Basic Painting (e.g., cost per surface area), Powder-Coat Cart Painting, Wet-Coat Line Painting, One-Sided Fraction Painting, Plating (4 types), Silk ScreeningAnodizing, Chem Film, Booth Painting , Protective Coat; Most Surface Treatments—both whole part and localized
Heat TreatmentAging, Annealing (3 types), Cyrogenic Freezing, Solutioning, Stress Relieving, Surface Hardening (3 types), Tempering (2 types) Through Hardening (4 types)Normalization, Chromizing, Borizing; Most Heat Treatments—both whole part and localized
InspectionIn Process Inspection for Sand Casting, Permanent Mold Casting, Heat TreatmentFinal Inspection, CMM, Ultrasonic Inspection, Liquid Penetrant Inspection, Magnetic Particle Inspection; Most Inspections—both whole part and localized
PackagingCarton Forming, Pack & Load (wrapping, bagging), Carton SealingTruck Loading, Bag & Tag, Intrim-State Packaging, Cleanroom Packaging; Most Packaging Models
LogisticsTransportation
User-Guided ProcessesBend Break, Turret Press, Stage Tooling, Progressive Die, Injection MoldingAvailable for all processes in aPriori automated
costing manufacturing process groups

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