Composite Part Cost Estimator
Estimating a composite part is harder than a machined part because cost is spread across expensive material, slow skilled layup, a long batch cure and tooling that wears out. This calculator builds a transparent per-part cost from those drivers so you can see which one is moving your quote.
Your numbers
Net area of one ply layer over the part, not including trim allowance.
Use total ply-area divided by part area if the schedule has pad-ups.
Fiber areal weight divided by (1 - resin content).
Carbon/epoxy prepreg varies widely with fiber grade and volume.
Offcuts, kit trim, expired or rejected plies.
Hand layup of prepreg is often 1 to 4 ply-m2 per hour. Automated tape laying is far higher.
Film, breather, bleeder, release, tape, sealant.
Energy, nitrogen or air, depreciation, maintenance, space.
Your results
Planning-level estimate. Replace defaults with your own rates and learning-curve data before using it in a binding quote.
Cost per part and autoclave share versus parts per run
Sweeps Parts per autoclave run from 1 to 24, holding your other inputs fixed.
Calibrate estimates with ERP actuals
Optional: see how routings, actual labor and material usage from your ERP can calibrate layup rates and waste factors.
Optional. The tool and every export work without this. No spam.
How to use the estimator
Enter the part area and the average number of plies over that area, then the prepreg areal weight and price. Add the waste percentage that reflects your nesting efficiency, the layup rate for your process, labor rate, the time for debulking and bagging, and consumables. For the cure, enter the autoclave hourly cost, the cycle time and the number of parts you can load per run. Tooling cost and tool life give an amortization per part. Finish with trim, inspect and finish hours and the margin you apply. The primary outputs are cost per part and the quoted price.
- Use the sweep to compare loading two, four or eight parts per autoclave run.
- Derive your own layup rate from time studies rather than copying a default.
- Add engineering, NRE and inspection setup separately for first-article quotes.
The cost model
Material kilograms are area times plies times prepreg areal weight, multiplied by one plus waste. Layup hours are the total ply area divided by the layup rate. Autoclave cost per part is cycle hours times hourly rate divided by parts per run, so it is the cost lever most sensitive to loading. Tooling per part is cost over life. Labor covers layup, bagging and finishing. The model leaves out freight, certification testing, rework, NDT and scrap beyond the waste factor, so add these as separate lines when they matter, and compare with your standard cost roll-up.
Reading the result
At the default inputs the part costs a few thousand dollars, with material and labor each a large share and the autoclave a modest share. Slide parts per run from one to eight and the autoclave cost per part falls steeply, then flattens, because fixed cycle cost is being spread. If layup labor dominates, a faster layup process, kit nesting software or automation is the lever. If material dominates, look at waste, ply nesting and prepreg width. If tooling dominates, the question is tool life and volume.
Common mistakes
Estimators often forget that autoclave loading is limited by tool footprint and thermal mass, not just by volume, so the parts-per-run number must be checked with the process engineer. Another trap is using nominal material usage without a ply-level nest, which hides real scrap. Layup rates quoted for large flat skins do not apply to small, contoured parts with many inserts. Finally, a learning curve applies: the first few parts take far longer than the steady state, so a low-volume quote should include a first-articles allowance.
Frequently Asked Questions
How do I estimate the cost of a carbon fiber part?
Add material (with waste), layup labor, bagging and consumables, cure cost per part, tooling amortization and finishing. Material is area times plies times areal weight times price. Cure cost depends heavily on how many parts share an autoclave run.
What is a typical waste factor for prepreg?
Hand-cut kits often lose 15% to 35% of the roll depending on part shape and ply nesting. Automated cutting with nesting software can reduce it. Track actual kit yield against roll usage to calibrate your own factor.
How is autoclave cost per hour calculated?
Add energy, gases, depreciation, maintenance, labor to run it and floor space, then divide by productive run hours. Many shops use between about 80 and 250 dollars per hour, but the right figure is your own fully loaded rate.
Does this work for infused or wet layup parts?
The structure applies, but replace prepreg inputs with fabric and resin cost and change the cure cost to oven or ambient cure. Layup rates and waste factors will differ, and consumables are often higher for infusion.
If you want standard cost, routing and quote history from your ERP to calibrate these rates automatically, Netray can help build a cost-estimating assistant over your own data.
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