Tooling Cost: $3,000-80,000 depending on complexity and cavity count. Amortize over production volume: for 100,000 parts, tooling adds $0.03-0.80/part.
Material Cost: Raw material + 5-10% scrap allowance. PP $1.20-1.80/kg, ABS $2.00-3.50/kg, PA66 $3.50-6.00/kg, PC $3.80-5.50/kg.
Machine Hour Rate: 50-ton $8-12/hr, 100-ton $10-15/hr, 200-ton $15-25/hr, 500-ton $30-50/hr.
Labor: Operator $2-4/hr, quality inspection $1-3/hr, packaging $0.50-1.50/hr.
Secondary Operations: Painting $0.50-3/part, printing $0.10-0.50/part, assembly $0.20-2/part. For a typical 50g ABS part: material $0.12, machine $0.08, labor $0.02, total = about $0.22/part (excluding tooling amortization).