Manufacturing Cost Models

aPriori’s physics-based cost models address a wide variety of 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 and evaluate the manufacturability of all routings defined in the Virtual Production Environment (VPE). This allows engineering, 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 “aPriori Manufacturing Cost Models” are included when a customer orders a Cost Model Group.  All manufacturing processes listed in the column titled “Additional Processes Which can be Delivered by Professional Services” are available through configuration by aPriori’s Professional Services team, and require a separate investment above and beyond the purchase of a license to the Cost Model 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.

 

Cost Model Groups aPriori Manufacturing Cost Models Additional Processes Which can be Delivered by Professional Services
Sheetmetal – Soft Tooled Process
Cut-to-Length, Shear, Oxyfuel/Plasma/Laser/Waterjet Cutting, Turret Press, Plasma-Punch, Laser-Punch, Bend Brake, 2- 3- and 4- Roller Bending, Deslag Straightening, Flame-Cut Beveling, Bump Bending, Laser Etching
Sheetmetal – Basic Stamping
Stage Tooling, Standard Press, 3D Laser  
Sheetmetal – Progressive Die Stamping
Progressive Die, Partial Progressive Die  
Sheetmetal – Transfer Die Stamping
Transfer Die, Offline Blanking Inline Blanking
Bar & Tube Fabrication Reciprocating/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 I Sand Casting Investment Casting
Casting II High Pressure Die Casting, Gravity Die Casting (aka Permanent Mold Casting)  
Plastic Molding Single Shot Injection Molding, Structural Foam Molding, Reaction Injection Molding Rubber Molding
Roto/Blow Molding Rotational Molding, Blow Molding  
Sheet Plastic  – Thermoforming
Vacuum Forming, Drape Molding  
Powder Metal Compaction Pressing, Furnace Sintering  
Forging Closed Die Hammer Forging  Open Die Hammer Forging, Rolled Ring Forging
Additive Manufacturing
SLA, SLS, 3D Printing, Shakeout, Breakoff, CT Scan SLM, DLMS
Machining – General Milling
CNC 3-axis Milling, CNC 4-axis Milling, CNC 5-axis Milling, Sawing/Cut-to-Length, Gun Drilling, Wire EDM, Drill Press, Deburring, Assembly Milling (User-Guided), Jig Boring Vertical & Horizontal Boring, Flow Drill, Lapping
Machining – General Turning CNC 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 Graphite Milling, Fine Thread Making
Machining – General Grinding
OD Grinding, ID Grinding, Surface Grinding, Single Index Milling, Rotor Grinding, Jig Grinding, Cylindrical Grinding Honing, Polishing, Jitterbug Sanding
Gear Making Hobbing, Shaping, Broaching, Rolling, Bevel Gear Cutting, Shaving, Profile Grinding, Threaded Wheel Grinding, Spline Rolling  
Printed Circuit Board Assembly Component Preparation, Surface Mount Assembly (single and double sided), Plated Through Hole Assembly, General Assembly (Conformal Coat, Depanelization, etc.), Testing
see aPriori Electronics Cost Modules datasheet for specifics
Component Library
Wire Harness Manufacturing Wire / Bundle / Conduit Prep, Wire Termination, Connector Assembly, Splice, Branch Covering, Braid, Harness Layout, Labeling, Testing
see aPriori Electronics Cost Modules datasheet for specifics
Wire Harness Data Table Loader, Component Library
Assembly Welding Weld Preparation, Manual MIG Welding, Manual Spot Welding, Robotic MIG Welding, Robotic Spot Welding, Weld Cleanup, Welding on Parts TIG Welding, Resistance, Ultrasonic and Friction Welding, Laser Welding, Brazing, Soldering, Electro-Beam Welding
Mechanical Assembly Manual Screw, Power Screw, Press Fit, Snap Fit, Rivet, Tab Bend, Nut Insert, Pick & Place Adhesives, Helicoil Insertion , Bonding, Grease Packing, Wire Routing; Most Mechanical Assembly Procedures
Chemical Milling
Chemical Milling  
Heat Treatment Aging, Annealing (3 types), Cryogenic 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
Surface Treatment Shot Blast, Degreasing, Basic Painting (e.g., cost per surface area), Powder-Coat Car Painting, Wet-Coat Line Painting, One-Sided Fraction Painting, Plating (4 types), Silk Screening, Passivation Chem Film, Booth Painting, Protective Coat; Most Surface Treatments—both whole part and localized
Anodizing Types I, IB, IC, II, IIB (“thin sulfuric” anodizing), and III (“hard coat” anodizing)  
Testing & Inspection
Fluorescent Penetrant Testing, Magnetic Penetrant Testing, Hydrostatic Leak Testing, X-ray Inspection
In Process Inspection for Sand Casting, Permanent Mold Casting included with Casting I and II
Final Inspection, CMM; Most Inspections—both whole part and localized
Packaging Carton Forming, Pack & Load (wrapping, bagging), Carton Sealing Truck Loading, Bag & Tag, Intrim-State Packaging, Cleanroom Packaging; Most Packaging Models
Logistics   Transportation
User-Guided Processes (for costing without CAD)
Turret Press, Bend Brake, Stage Tooling, Progressive Die, Injection Molding  

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