When producing plastic molds, understanding the various cost factors is the key to controlling your budget and improving efficiency. Often times, the secret to controlling costs is hidden in the details. If you can sort out which factors directly affect costs, you can better optimize production and avoid unnecessary expenses. Here’s a look at the four key factors that affect plastic mold costs!
1. Material selection and part weight
Material is one of the most direct factors in plastic mold cost. The price of different types of plastic varies greatly, from $1 to $25 per pound. Therefore, choosing the right material is not only related to product quality, but also has a direct impact on production costs. For example, for parts that weigh less, the impact of material costs is relatively small, while for large, heavy parts, material costs will account for a large portion of the cost.
Moreover, the choice of material will also affect the production efficiency. Some materials allow for faster production and shorter production time per part. Remember, lightweight design can effectively reduce material usage and lower overall costs.
Calculation formula:
Material Cost = Plastic Unit Price × Part Weight (lbs)
2. Cycle time and mold cavities
“Cycle time” is actually the time it takes a machine to complete a production run. In injection molding, cycle time consists of multiple steps such as mold closure, injection, cooling, mold opening, and demolding. Each step takes time, and by reducing the time for each step, the overall production efficiency can be improved.
In addition, the number of cavities in a mold also affects productivity. How many cavities in a mold can produce how many parts at once. If there are multiple cavities in a mold, then more parts are produced in each production cycle and the cost per unit of product is lower. Therefore, optimizing the number of cavities in a mold is a good way to reduce costs.
Calculation formula:
Parts produced per hour = (3600 seconds / cycle time) × number of mold cavities
Non-Material Costs = Machine Rate / Parts Per Hour
3. Non-material related costs
In addition to materials and production time, equipment costs and plant expenses are also part of production costs. Investment in machines such as injection molding machines and auxiliary equipment is very high, especially modern servo-driven injection molding machines, which can cost $100,000 for small machines and possibly millions for large machines. Machines have a limited lifespan and their efficiency decreases as technology advances.
In addition, there are fixed and variable costs, such as plant rent, power consumption, and employee salaries, which are all factors that affect production costs. Overall, the operating cost of machinery and equipment is the “machine rate”, which is the cost per hour of the production process.
Calculation formula:
Machine Rate = Equipment Investment ÷ Equipment Life Cycle
Non-Material Costs = Machine Rate / Parts Produced per Hour
4. Packaging and Surcharges
Very often, the final price of a product is not only the cost of production, but also additional costs such as packaging and post-processing. For example, layered packaging, retail packaging, painting, printing logos, and even post-finishing all add to the cost. While these add-ons can enhance the look and market value of a product, they can also push up the overall cost of production.
When estimating costs, don’t forget to factor in these extras as well. While some of them may seem like small expenses, once they are produced on a large scale, the overall cost can add up quite a bit.
Summarizing Production Costs
To accurately estimate the production cost of plastic molds, you first have to know the types and quantities of materials you’re using, then figure out the production cycle time for each part, and then consider the cost of machinery and equipment, and the overhead of plant and electricity. Finally, you have to add the cost of packaging and additional services. All of these factors add up to the final cost of your product.
By gaining a deeper understanding and optimizing these cost factors, you will not only be able to control your costs, but also increase your productivity and ensure that your products are more competitive in the marketplace. Overall, by mastering these, you will be able to make your way through production without fear of unexpected overhead.
Post time: Mar-24-2025