How to Calculate the Production Cost of a 3D Printed Item: A Comprehensive Guide

3D printing has revolutionized manufacturing, providing rapid prototyping and small-scale production capabilities that were previously expensive or unattainable. However, understanding the true cost of producing a 3D printed item is crucial for both hobbyists and businesses. This blog post aims to guide you through the key components that contribute to the total production cost of a 3D printed item.

1. Material Costs

The most straightforward part of calculating the production cost is the material used in printing. The cost of the filament, resin, or powder depends on the type and quality of the material. For example:

• FDM Filament (PLA, ABS, PETG): Typically ranges from $15 to $40 per kilogram.

• Resin (SLA/DLP): Costs can vary from $50 to $150 per liter.

• Powders (SLS, DMLS): Metal powders can range between $50 to $500 per kilogram, depending on the material.

Formula to Calculate Material Cost: Material cost = (Weight of the item in grams) × (Price of material per gram)

For example, if your 3D printed object weighs 100 grams and the filament costs $0.03 per gram, the material cost would be: 100g×0.03=$3.00100 \text{g} \times 0.03 = \text{\$3.00}100g×0.03=$3.00

Considerations:

• Material waste: In some technologies like SLA and SLS, extra material is required for supports or unsintered powder, which increases waste.

• Support structures: Additional material is often needed for printing overhangs or complex geometries.

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2. Machine Costs

Machine operating costs are often overlooked but essential in calculating the full cost. Each 3D printer has an upfront purchase price, maintenance cost, and operational lifespan. While it's challenging to pinpoint a precise cost per hour for every printer, there are general guidelines for estimating.

Key Factors:

• Depreciation: Assume your 3D printer will operate for a certain number of hours over its lifetime. This helps to spread the initial purchase cost over time.

• Electricity Usage: 3D printers consume power, and their consumption varies by type (FDM, SLA, SLS). For example, a typical FDM printer might use 50-200W, while SLS and metal printers may consume significantly more.

Formula to Calculate Machine Cost: Machine cost per hour = (Cost of the 3D printer + Maintenance cost) / Expected operational hours.

If your FDM printer cost $1,000 and you expect to run it for 2,000 hours over its lifetime, the machine cost per hour would be: 10002000=0.50 per hour\frac{1000}{2000} = 0.50 \text{ per hour}20001000​=0.50 per hour

Energy cost per hour: For a 150W printer running at a $0.12/kWh electricity rate, the energy cost per hour would be: 150W1000×0.12=0.018 per hour\frac{150 \text{W}}{1000} \times 0.12 = 0.018 \text{ per hour}1000150W​×0.12=0.018 per hour

Total machine cost per hour = Depreciation + Energy cost

3. Print Time (Labor) Costs

The printing time impacts the labor cost, especially if the 3D printer requires supervision. For complex or large items that take hours or even days to print, this becomes a significant factor.

Key Factors:

• Printer speed: Printer specifications usually give an idea of the speed (mm/sec), which affects the total print time.

• Post-processing: Post-processing tasks such as removing supports, curing (for resin prints), or sanding must also be accounted for.

Formula to Calculate Print Time Cost: Labor cost = (Print time in hours) × (Hourly labor rate)

For example, if a print takes 5 hours and your labor rate is $20/hour, the labor cost is: 5×20=$1005 \times 20 = \text{\$100}5×20=$100

Depending on the 3D printing method, post-processing can add significant time and cost to the overall production. Processes like removing support structures, sanding, painting, or curing (SLA prints) all require additional materials and labor.

Examples of Post-Processing:

• FDM: Sanding, priming, and painting.

• SLA: Curing in UV light, removing supports, and polishing.

• SLS/DMLS: Removing powder and additional machining for metal prints.

Post-processing materials (e.g., paints, coatings, solvents) should also be factored into the total cost.

5. Overhead Costs

Overhead costs include a variety of business expenses, from the rent of the facility to utilities, insurance, software licenses, and other indirect costs associated with production. While not always easy to quantify, they can be divided by the total hours of machine operation to arrive at an estimated overhead cost per hour.

Formula for Overhead Costs: Overhead per hour = (Total monthly overhead costs) / (Total machine operation hours per month)

For example, if your business overhead is $1,000 per month and you operate your machines for 200 hours per month, the overhead cost per hour is: 1000200=$5 per hour\frac{1000}{200} = \text{\$5 per hour}2001000​=$5 per hour

6. Profit Margin

Finally, to arrive at the final price of a 3D printed item, you should account for profit. A typical profit margin for small-scale production is around 20% to 50%, depending on the industry.

Formula for Final Cost: Final cost = (Material cost + Machine cost + Labor cost + Overhead) × (1 + Profit margin)

For example, if the total production cost is $10 and you want a 30% profit margin, the final price would be: 10×(1+0.30)=$1310 \times (1 + 0.30) = \text{\$13}10×(1+0.30)=$13

Conclusion

Calculating the production cost of a 3D printed item involves accounting for several variables, including material, machine, labor, post-processing, and overhead costs. By understanding these factors, you can create more accurate pricing models, ensure profitability, and provide fair prices to your customers.

By breaking down each element of the process, you can make informed decisions about whether a particular 3D printing project is cost-effective and how to optimize your resources for better results.