The advent of additive manufacturing, commonly known as 3D printing, has revolutionized industries ranging from aerospace to healthcare, offering unprecedented flexibility in design and production. However, one of the most critical considerations for businesses, hobbyists, and researchers alike is the cost associated with utilizing various 3D printing technologies. Understanding how to calculate the price of 3D printing is not a straightforward task; it involves a complex interplay of material costs, machine depreciation, labor, energy consumption, post-processing, and overhead. This article delves into the pricing mechanisms for eight prominent 3D printing technologies: Selective Laser Sintering (SLS), Stereolithography (SLA), Selective Laser Melting (SLM), Multi Jet Fusion (MJF), Fused Deposition Modeling (FDM), Binder Jetting (BJ), Digital Light Processing (DLP), and PolyJet. Each method has unique characteristics that influence its cost structure, and by examining these in detail, we aim to provide a scientific, rigorous framework for cost estimation.
Pricing a 3D-printed part requires a blend of empirical data, mathematical modeling, and practical experience. Costs can vary significantly depending on whether the printing is done in-house or outsourced to a service provider, the complexity of the design, the volume of production, and the specific application requirements (e.g., prototyping versus end-use parts). In this article, we’ll break down the cost components for each technology, explore the variables that drive pricing, and offer step-by-step methodologies to calculate expenses accurately. By the end, readers will have a comprehensive toolkit to assess the financial implications of adopting any of these eight 3D printing methods.
General Cost Components in 3D Printing
Before diving into the specifics of each technology, it’s essential to establish a universal framework for cost calculation in 3D printing. The total cost of a printed part can generally be expressed as:
Ctotal=Cmaterial+Cmachine+Clabor+Cenergy+Cpost−processing+Coverhead C_{total} = C_{material} + C_{machine} + C_{labor} + C_{energy} + C_{post-processing} + C_{overhead}
- Material Cost (CmaterialC_{material}): The expense of raw materials, such as filaments, resins, powders, or binders, used in the printing process.
- Machine Cost (CmachineC_{machine}): The amortized cost of the 3D printer, including purchase price, maintenance, and operational lifespan.
- Labor Cost (ClaborC_{labor}): Wages for operators, designers, or technicians involved in setup, monitoring, and finishing.
- Energy Cost (CenergyC_{energy}): Electricity consumed during printing and auxiliary processes.
- Post-Processing Cost (Cpost−processingC_{post-processing}): Expenses related to cleaning, curing, sanding, painting, or other finishing steps.
- Overhead Cost (CoverheadC_{overhead}): Facility costs, software licenses, and administrative expenses.
This formula serves as a baseline, but each technology modifies these components based on its unique workflow, material requirements, and equipment demands. Let’s explore each method in turn, starting with Selective Laser Sintering (SLS).
Selective Laser Sintering (SLS)
Selective Laser Sintering (SLS) is a powder-based 3D printing technology that uses a laser to fuse polymer particles into a solid object layer by layer. It’s widely used for functional prototypes and small-batch production due to its ability to produce strong, complex parts without support structures. Calculating the cost of SLS printing involves several nuanced factors.
Material Cost in SLS
SLS typically employs polymer powders such as nylon (PA11 or PA12), which are relatively expensive compared to filament-based methods. The cost of powder ranges from $50 to $150 per kilogram, depending on the material grade and supplier. However, a key advantage of SLS is powder reusability. After a print, unused powder can be sieved and mixed with fresh powder (often at a 50:50 ratio), reducing waste. The material cost per part can be calculated as:
Cmaterial=Vpart×ρ×Ppowder×(1−R) C_{material} = V_{part} \times \rho \times P_{powder} \times (1 – R)
Where:
- VpartV_{part} = Volume of the part (in cubic centimeters),
- ρ\rho = Density of the material (e.g., 1 g/cm³ for nylon),
- PpowderP_{powder} = Price per kilogram of powder,
- RR = Reuse factor (e.g., 0.5 if 50% of powder is reused).
For example, a 100 cm³ part printed in nylon costing $100/kg with 50% powder reuse would incur a material cost of:
Cmaterial=100×1×100×(1−0.5)=50 USD C_{material} = 100 \times 1 \times 100 \times (1 – 0.5) = 50 \, \text{USD}
Machine Cost in SLS
SLS printers are industrial-grade machines, with prices ranging from $50,000 for entry-level systems to over $500,000 for high-end models. To calculate the machine cost per part, we amortize the printer’s cost over its operational lifespan (typically 5–10 years or 20,000–50,000 hours). The hourly machine cost is:
Cmachine/hour=Pprinter+CmaintenanceLhours C_{machine/hour} = \frac{P_{printer} + C_{maintenance}}{L_{hours}}
Where:
- PprinterP_{printer} = Purchase price,
- CmaintenanceC_{maintenance} = Cumulative maintenance cost (e.g., 10–20% of printer cost annually),
- LhoursL_{hours} = Total operational hours.
For a $200,000 printer with $20,000 annual maintenance over 5 years (assuming 2,000 hours/year, or 10,000 hours total):
Cmachine/hour=200,000+(20,000×5)10,000=30 USD/hour C_{machine/hour} = \frac{200,000 + (20,000 \times 5)}{10,000} = 30 \, \text{USD/hour}
If a part takes 10 hours to print, the machine cost is $300.
Energy and Labor in SLS
SLS printers consume significant energy due to the laser and heated build chamber (typically 2–5 kW). At an electricity rate of $0.15/kWh, a 10-hour print at 3 kW costs:
Cenergy=3×10×0.15=4.5 USD C_{energy} = 3 \times 10 \times 0.15 = 4.5 \, \text{USD}
Labor costs depend on setup and post-processing time. An operator earning $25/hour might spend 1 hour on setup and 2 hours on powder removal and finishing, totaling $75.
Post-Processing and Overhead
Post-processing in SLS includes powder removal (manual or via bead blasting) and optional dyeing or surface smoothing. These costs might add $10–$50 per part. Overhead, including facility rent and software, could contribute an additional 10–20% of direct costs.
Total SLS Cost Example
For a 100 cm³ part:
- Material: $50
- Machine: $300
- Energy: $4.50
- Labor: $75
- Post-Processing: $20
- Overhead: $45 (15% of $449.50)
- Total: $494.50
Stereolithography (SLA)
Stereolithography (SLA) uses a laser to cure liquid photopolymer resin into solid parts, excelling in high-resolution applications like dental models and jewelry. Its cost structure differs from SLS due to the resin-based process.
Material Cost in SLA
Resins range from $50 to $300 per liter, with specialty resins (e.g., biocompatible or flexible) at the higher end. Unlike SLS, unused resin can often be reused, but it degrades over time, requiring filtration. The material cost is:
Cmaterial=Vpart×Presin C_{material} = V_{part} \times P_{resin}
For a 50 cm³ part with $150/liter resin:
Cmaterial=0.05×150=7.5 USD C_{material} = 0.05 \times 150 = 7.5 \, \text{USD}
Machine Cost in SLA
SLA printers range from $3,000 (desktop) to $100,000 (industrial). For a $10,000 printer over 5,000 hours:
Cmachine/hour=10,000+2,0005,000=2.4 USD/hour C_{machine/hour} = \frac{10,000 + 2,000}{5,000} = 2.4 \, \text{USD/hour}
A 5-hour print costs $12.
Energy, Labor, and Post-Processing
SLA uses less energy (0.5–1 kW), so a 5-hour print at 0.75 kW and $0.15/kWh costs $0.56. Labor includes washing and curing (e.g., 1 hour at $25/hour = $25). Post-processing (e.g., support removal, sanding) might add $5–$15.
Total SLA Cost Example
- Material: $7.50
- Machine: $12
- Energy: $0.56
- Labor: $25
- Post-Processing: $10
- Overhead: $7 (15% of $55.06)
- Total: $62.06
Selective Laser Melting (SLM)
Selective Laser Melting (SLM) fuses metal powders using a laser, ideal for aerospace and medical implants. Its high material and equipment costs make it distinct.
Material Cost in SLM
Metal powders (e.g., titanium, stainless steel) cost $100–$500/kg. A 50 cm³ titanium part (density 4.5 g/cm³, $300/kg):
Cmaterial=50×4.5×0.001×300=67.5 USD C_{material} = 50 \times 4.5 \times 0.001 \times 300 = 67.5 \, \text{USD}
Machine Cost in SLM
SLM machines cost $500,000–$2,000,000. For a $1,000,000 machine over 20,000 hours:
Cmachine/hour=1,000,000+200,00020,000=60 USD/hour C_{machine/hour} = \frac{1,000,000 + 200,000}{20,000} = 60 \, \text{USD/hour}
A 20-hour print costs $1,200.
Energy and Beyond
Energy (5–10 kW) for 20 hours at 7 kW costs $21. Labor and extensive post-processing (e.g., heat treatment, machining) could exceed $200.
Total SLM Cost Example
- Material: $67.50
- Machine: $1,200
- Energy: $21
- Labor: $200
- Post-Processing: $150
- Overhead: $258 (15%)
- Total: $1,896.50
Multi Jet Fusion (MJF)
Multi Jet Fusion (MJF), developed by HP, is a powder-based technology that uses inkjet heads to apply fusing and detailing agents onto a polymer powder bed, followed by thermal energy to solidify the material. MJF is renowned for its speed, isotropic mechanical properties, and suitability for functional parts, making it a competitor to SLS. Its cost structure shares similarities with SLS but has distinct differences due to its unique process and material efficiency.
Material Cost in MJF
MJF primarily uses nylon powders (e.g., PA12), similar to SLS, with costs ranging from $60 to $120 per kilogram. Like SLS, MJF benefits from powder reusability, though the refresh rate (the proportion of fresh powder required) is typically higher (e.g., 20–30% fresh powder per build). The material cost per part can be expressed as:
Cmaterial=Vpart×ρ×Ppowder×(1−R+F) C_{material} = V_{part} \times \rho \times P_{powder} \times (1 – R + F)
Where:
- VpartV_{part} = Volume of the part (in cm³),
- ρ\rho = Material density (e.g., 1 g/cm³ for PA12),
- PpowderP_{powder} = Price per kilogram,
- RR = Reuse factor (e.g., 0.7 for 70% reused powder),
- FF = Fresh powder factor (e.g., 0.3 for 30% fresh powder).
For a 150 cm³ part with PA12 at $100/kg, 70% reuse, and 30% fresh powder:
Cmaterial=150×1×100×(1−0.7+0.3)=150×0.6×100=90 USD C_{material} = 150 \times 1 \times 100 \times (1 – 0.7 + 0.3) = 150 \times 0.6 \times 100 = 90 \, \text{USD}
Additionally, MJF requires fusing and detailing agents, which add roughly $0.05–$0.10 per cm³ of part volume. For our example, this could be an extra $7.50–$15.
Machine Cost in MJF
MJF printers, such as the HP Jet Fusion 4200, cost between $150,000 and $400,000. Amortizing a $300,000 printer with $30,000 annual maintenance over 10,000 hours:
Cmachine/hour=300,000+(30,000×5)10,000=45 USD/hour C_{machine/hour} = \frac{300,000 + (30,000 \times 5)}{10,000} = 45 \, \text{USD/hour}
MJF’s speed allows multiple parts to be printed in a single build. If a 150 cm³ part is part of a 10-hour build, the machine cost is $450, potentially divided among multiple parts if the build volume is maximized.
Energy and Labor in MJF
MJF printers consume 5–10 kW due to the thermal fusion process. A 10-hour print at 7 kW and $0.15/kWh costs:
Cenergy=7×10×0.15=10.5 USD C_{energy} = 7 \times 10 \times 0.15 = 10.5 \, \text{USD}
Labor includes setup (e.g., 0.5 hours) and post-processing (e.g., 1.5 hours for powder removal and bead blasting) at $25/hour, totaling $50.
Post-Processing and Overhead
Post-processing in MJF is minimal compared to metal-based methods but includes powder removal and optional dyeing or smoothing, adding $10–$30 per part. Overhead might contribute $80 (15% of direct costs).
Total MJF Cost Example
For a 150 cm³ part:
- Material: $90 + $10 (agents) = $100
- Machine: $450
- Energy: $10.50
- Labor: $50
- Post-Processing: $20
- Overhead: $84 (15% of $630.50)
- Total: $714.50
Fused Deposition Modeling (FDM)
Fused Deposition Modeling (FDM) is the most accessible and widely used 3D printing technology, extruding thermoplastic filament through a heated nozzle to build parts layer by layer. Its affordability makes it popular for hobbyists, educators, and prototyping, but industrial-grade FDM systems also serve advanced applications.
Material Cost in FDM
FDM uses filaments like PLA ($20–$30/kg), ABS ($25–$40/kg), or advanced materials like PEEK ($300–$500/kg). The material cost is straightforward:
Cmaterial=Vpart×ρ×Pfilament C_{material} = V_{part} \times \rho \times P_{filament}
For a 200 cm³ PLA part (density 1.24 g/cm³) at $25/kg:
Cmaterial=200×1.24×0.001×25=6.2 USD C_{material} = 200 \times 1.24 \times 0.001 \times 25 = 6.2 \, \text{USD}
Support material (if used) adds 10–50% to the cost, depending on geometry.
Machine Cost in FDM
FDM printers range from $200 (hobbyist) to $50,000 (industrial). For a $2,000 printer over 5,000 hours:
Cmachine/hour=2,000+5005,000=0.5 USD/hour C_{machine/hour} = \frac{2,000 + 500}{5,000} = 0.5 \, \text{USD/hour}
A 15-hour print costs $7.50. Industrial systems like a $20,000 printer over 10,000 hours cost $2.50/hour, or $37.50 for 15 hours.
Energy and Labor in FDM
FDM printers use 0.1–0.5 kW. A 15-hour print at 0.3 kW and $0.15/kWh costs $0.68. Labor is minimal for hobbyists (e.g., 0.5 hours at $25/hour = $12.50) but higher for industrial setups with support removal and finishing (e.g., 2 hours = $50).
Post-Processing and Overhead
Post-processing might include support removal, sanding, or painting ($5–$20). Overhead adds 15%, or $3–$15 depending on scale.
Total FDM Cost Example
For a 200 cm³ PLA part (hobbyist setup):
- Material: $6.20
- Machine: $7.50
- Energy: $0.68
- Labor: $12.50
- Post-Processing: $10
- Overhead: $5 (15% of $36.88)
- Total: $41.88
Binder Jetting (BJ)
Binder Jetting (BJ) deposits a liquid binding agent onto a powder bed to form parts, often used for metal or ceramic components after sintering. It’s cost-effective for high-volume production but involves complex post-processing.
Material Cost in BJ
Powder costs vary (e.g., sand at $10/kg, stainless steel at $50–$100/kg). A 100 cm³ steel part (density 8 g/cm³) at $80/kg:
Cmaterial=100×8×0.001×80=64 USD C_{material} = 100 \times 8 \times 0.001 \times 80 = 64 \, \text{USD}
Binder adds $0.02–$0.05 per cm³, or $2–$5.
Machine Cost in BJ
BJ printers range from $100,000 to $1,000,000. For a $400,000 printer over 15,000 hours:
Cmachine/hour=400,000+80,00015,000=32 USD/hour C_{machine/hour} = \frac{400,000 + 80,000}{15,000} = 32 \, \text{USD/hour}
A 12-hour print costs $384.
Energy and Beyond
Energy (2–5 kW) for 12 hours at 3 kW costs $5.40. Labor and sintering (e.g., 3 hours at $25/hour + $50 furnace cost) total $125. Post-processing (infiltration or sintering) adds $50–$100.
Total BJ Cost Example
- Material: $64 + $3 = $67
- Machine: $384
- Energy: $5.40
- Labor: $125
- Post-Processing: $75
- Overhead: $93 (15%)
- Total: $749.40
Digital Light Processing (DLP)
Digital Light Processing (DLP) is similar to SLA but uses a projector to cure resin, offering faster print times for small, detailed parts like dental molds.
Material Cost in DLP
Resins cost $50–$250/liter. A 50 cm³ part at $120/liter:
Cmaterial=0.05×120=6 USD C_{material} = 0.05 \times 120 = 6 \, \text{USD}
Machine Cost in DLP
DLP printers range from $3,000 to $50,000. For a $5,000 printer over 5,000 hours:
Cmachine/hour=5,000+1,0005,000=1.2 USD/hour C_{machine/hour} = \frac{5,000 + 1,000}{5,000} = 1.2 \, \text{USD/hour}
A 4-hour print costs $4.80.
Energy and Beyond
Energy (0.5–1 kW) for 4 hours at 0.75 kW costs $0.45. Labor and post-processing (1.5 hours at $25/hour + $10) total $47.50.
Total DLP Cost Example
- Material: $6
- Machine: $4.80
- Energy: $0.45
- Labor/Post-Processing: $47.50
- Overhead: $8 (15%)
- Total: $66.75
PolyJet
PolyJet jets photopolymer droplets cured by UV light, excelling in multi-material and high-resolution prints.
Material Cost in PolyJet
Resins cost $200–$400/kg. A 75 cm³ part at $300/kg:
Cmaterial=75×1×0.001×300=22.5 USD C_{material} = 75 \times 1 \times 0.001 \times 300 = 22.5 \, \text{USD}
Machine Cost in PolyJet
PolyJet printers cost $50,000–$250,000. For a $100,000 printer over 10,000 hours:
Cmachine hour=100,000+20,00010,000=12 USD/hour C_{machine/hour} = \frac{100,000 + 20,000}{10,000} = 12 \, \text{USD/hour}
A 6-hour print costs $72.
Energy and Beyond
Energy (1–2 kW) for 6 hours at 1.5 kW costs $1.35. Labor and support removal (2 hours at $25/hour + $15) total $65.
Total PolyJet Cost Example
- Material: $22.50
- Machine: $72
- Energy: $1.35
- Labor/Post-Processing: $65
- Overhead: $24 (15%)
- Total: $184.85
Refining Cost Models: Advanced Variables
The basic cost formula (Ctotal=Cmaterial+Cmachine+Clabor+Cenergy+Cpost−processing+CoverheadC_{total} = C_{material} + C_{machine} + C_{labor} + C_{energy} + C_{post-processing} + C_{overhead}) provides a solid foundation, but real-world 3D printing involves dynamic factors that can significantly alter expenses. Let’s explore these advanced variables and integrate them into our calculations for each technology.
Build Volume Optimization
Most 3D printing technologies benefit from maximizing the build volume—printing multiple parts in a single run to distribute machine and overhead costs. This is particularly impactful for powder-based methods (SLS, MJF, SLM, BJ) and resin-based methods with large vats (SLA, DLP, PolyJet). The cost per part decreases as the number of parts (NN) increases:
Cpart=Cmaterial/total+Cmachine/run+Cenergy/run+Clabor/run+Cpost−processing/run+Coverhead/runN C_{part} = \frac{C_{material/total} + C_{machine/run} + C_{energy/run} + C_{labor/run} + C_{post-processing/run} + C_{overhead/run}}{N}
Failure Rates and Rework
Print failures—due to design errors, machine malfunctions, or material issues—add hidden costs. The failure rate (FrF_r) varies by technology (e.g., 5% for FDM, 10% for SLM) and increases total cost:
Cadjusted=Ctotal×(1+Fr) C_{adjusted} = C_{total} \times (1 + F_r)
Economies of Scale
For high-volume production, material and machine costs often decrease due to bulk discounts and optimized workflows. We’ll denote this scaling factor as SfS_f (e.g., 0.9 for 10% savings).
Environmental Factors
Energy costs fluctuate by region, and waste disposal (e.g., resin or metal powder) may incur fees. We’ll include an environmental adjustment (EaE_a) where relevant.
Now, let’s revisit each technology with these refinements.
Selective Laser Sintering (SLS) Revisited
Build Volume Optimization in SLS
SLS excels at nesting multiple parts in its powder bed. Suppose a 500 cm³ build chamber prints five 100 cm³ parts in 12 hours. Material cost scales linearly (5 × $50 = $250), but machine cost ($30/hour × 12 = $360) is split:
Cmachine/part=3605=72 USD C_{machine/part} = \frac{360}{5} = 72 \, \text{USD}
Energy ($5.40), labor ($75), and post-processing ($20/part) adjust accordingly, reducing the per-part cost to:
-
- Material: $50
-
- Machine: $72
-
- Energy: $1.08 ($5.40 ÷ 5)
-
- Labor: $15 ($75 ÷ 5)
-
- Post-Processing: $20
-
- Overhead: $23 (15%)
-
- Total: $181.08 (versus $494.50 for one part)
Failure Rate
SLS has a low failure rate (e.g., 3%) due to its robust process. Adjusted cost:
Cadjusted=181.08×1.03=186.51 USD C_{adjusted} = 181.08 \times 1.03 = 186.51 \, \text{USD}
Economies of Scale
For 100 parts, powder costs might drop to $90/kg (Sf=0.9S_f = 0.9), reducing material cost to $45/part, yielding a total of $171.51/part after adjustments.
Environmental Factors
Powder disposal fees ($0.50/kg) for 50 kg of waste add $25 per build, or $5/part, bringing the cost to $176.51.
Stereolithography (SLA) Revisited
Build Volume Optimization in SLA
A 1-liter resin vat prints ten 50 cm³ parts in 6 hours. Material cost is $75 (10 × $7.50), machine cost is $14.40 ($2.40/hour × 6), and per-part cost drops:
-
- Material: $7.50
-
- Machine: $1.44
-
- Energy: $0.06
-
- Labor: $2.50
-
- Post-Processing: $10
-
- Overhead: $3 (15%)
-
- Total: $24.50 (versus $62.06)
Failure Rate
SLA’s failure rate (e.g., 7%) due to resin curing issues adjusts this to $26.22.
Economies of Scale
Bulk resin at $120/liter (Sf=0.8S_f = 0.8) lowers material cost to $6/part, yielding $24.22/part.
Environmental Factors
Resin disposal ($1/liter) adds $0.10/part, making it $24.32.
Selective Laser Melting (SLM) Revisited
Build Volume Optimization in SLM
A 20-hour build with five 50 cm³ parts: material cost is $337.50 (5 × $67.50), machine cost is $1,200, and per-part cost is:
-
- Material: $67.50
-
- Machine: $240
-
- Energy: $4.20
-
- Labor: $40
-
- Post-Processing: $150
-
- Overhead: $76 (15%)
-
- Total: $577.70 (versus $1,896.50)
Failure Rate
SLM’s 10% failure rate (due to thermal stresses) adjusts this to $635.47.
Economies of Scale
Bulk titanium at $270/kg reduces material to $60.75/part, yielding $582.22.
Environmental Factors
Metal powder recycling fees ($2/kg) add $9/part, making it $591.22.
Multi Jet Fusion (MJF) Revisited
Build Volume Optimization in MJF
A 10-hour build with five 150 cm³ parts: material cost is $550 (5 × $110), machine cost is $450, and per-part cost is:
-
- Material: $110
-
- Machine: $90
-
- Energy: $2.10
-
- Labor: $10
-
- Post-Processing: $20
-
- Overhead: $29
-
- Total: $261.10 (versus $714.50)
Failure Rate
MJF’s 4% failure rate adjusts this to $271.54.
Economies of Scale
Powder at $90/kg reduces material to $99/part, yielding $258.54.
Environmental Factors
Agent disposal ($0.50/build) adds $0.10/part, making it $258.64.
Fused Deposition Modeling (FDM) Revisited
Build Volume Optimization in FDM
A hobbyist printer runs three 200 cm³ parts in 20 hours: material cost is $18.60 (3 × $6.20), machine cost is $10, and per-part cost is:
-
- Material: $6.20
-
- Machine: $3.33
-
- Energy: $0.23
-
- Labor: $4.17
-
- Post-Processing: $10
-
- Overhead: $4
-
- Total: $27.93 (versus $41.88)
Failure Rate
FDM’s 5% failure rate adjusts this to $29.33.
Economies of Scale
Bulk PLA at $20/kg reduces material to $5/part, yielding $27.53.
Environmental Factors
Minimal waste keeps costs stable at $27.53.
Binder Jetting (BJ) Revisited
Build Volume Optimization in BJ
A 12-hour build with five 100 cm³ parts: material cost is $335 (5 × $67), machine cost is $384, and per-part cost is:
-
- Material: $67
-
- Machine: $76.80
-
- Energy: $1.08
-
- Labor: $25
-
- Post-Processing: $75
-
- Overhead: $37
-
- Total: $281.88 (versus $749.40)
Failure Rate
BJ’s 6% failure rate adjusts this to $298.79.
Economies of Scale
Powder at $72/kg reduces material to $60/part, yielding $287.39.
Environmental Factors
Sintering emissions fees ($5/build) add $1/part, making it $288.39.
Digital Light Processing (DLP) Revisited
Build Volume Optimization in DLP
A 4-hour build with ten 50 cm³ parts: material cost is $60, machine cost is $4.80, and per-part cost is:
-
- Material: $6
-
- Machine: $0.48
-
- Energy: $0.05
-
- Labor: $4.75
-
- Post-Processing: $10
-
- Overhead: $3
-
- Total: $24.28 (versus $66.75)
Failure Rate
DLP’s 6% failure rate adjusts this to $25.74.
Economies of Scale
Resin at $96/liter reduces material to $4.80/part, yielding $24.14.
Environmental Factors
Resin disposal adds $0.10/part, making it $24.24.
PolyJet Revisited
Build Volume Optimization in PolyJet
A 6-hour build with five 75 cm³ parts: material cost is $112.50, machine cost is $72, and per-part cost is:
-
- Material: $22.50
-
- Machine: $14.40
-
- Energy: $0.27
-
- Labor: $13
-
- Post-Processing: $15
-
- Overhead: $9
-
- Total: $74.17 (versus $184.85)
Failure Rate
PolyJet’s 5% failure rate adjusts this to $77.88.
Economies of Scale
Resin at $270/kg reduces material to $20.25/part, yielding $75.13.
Environmental Factors
Waste disposal adds $0.50/part, making it $75.63.
Comparative Analysis
| Technology | Single Part Cost | Optimized Batch Cost |
|---|---|---|
| SLS | $494.50 | $176.51 |
| SLA | $62.06 | $24.32 |
| SLM | $1,896.50 | $591.22 |
| MJF | $714.50 | $258.64 |
| FDM | $41.88 | $27.53 |
| BJ | $749.40 | $288.39 |
| DLP | $66.75 | $24.24 |
| PolyJet | $184.85 | $75.63 |
This table highlights how batch production slashes costs, especially for high-end technologies like SLM and MJF.
