Unit Costs and Tooling Costs in Thermoforming: Cost Factors and Scalability

Relationship Between Unit Costs and Tooling Costs in Thermoforming – Key Facts at a Glance

• The costs of thermoforming mainly consist of tooling, material, manufacturing, energy and labor costs
• Tooling costs are incurred once and typically range between €800 and €10,000
• Unit costs usually range between €0.20 and €15 per part depending on material, geometry and production volume. For particularly large or complex parts costs may be higher
• As production volume increases unit costs decrease significantly especially when moving from very small batches to small series

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What Factors Determine Thermoforming Costs?

Several cost factors interact in the production of thermoformed plastic parts. These determine both the total cost of a thermoforming project and how unit costs evolve with increasing production volume.

Tooling Costs as Initial Investment

Tooling costs in thermoforming are a one time initial investment. They occur at the beginning of a project and do not recur afterward. Typical thermoforming tools cost between approximately €800 and €10,000 depending on size, complexity and number of cavities. Higher costs usually result from more complex tool designs.

Material, geometry and the machine for which the tool is designed also have a major influence. Additional components such as stacking systems or substructures can further increase the price. With increasing production volume these fixed costs are distributed over more parts which significantly reduces the tooling cost share per unit.

What Does a Thermoformed Part Cost per Unit?

Unit costs in thermoforming depend on several factors:

• Material used
• Initial material thickness
• Part size and geometry
• Degree of automation in production
• Production quantity
• etc

For standard trays, inlays and containers unit costs typically range between €0.20 and €15 per piece. For large housings or heavily post processed parts costs can be significantly higher. The exact price depends on the specific project and part requirements

How Costs Develop with Increasing Production Volume

As production volume increases unit costs in thermoforming decrease. Machine downtime is spread over more parts and automated processes enable higher output per hour.

At the same time the cost structure changes. In smaller series tooling costs make up a large share. In larger series material costs become the dominant factor.

Unit Cost Reduction Between Small and Medium Series

The greatest reduction in unit costs typically occurs when moving from very small quantities to small series. Even the step from a micro series of less than 10 parts to a small series of less than 100 parts can bring significant cost advantages.

Another economic leap often occurs when transitioning to medium series with up to approximately 5,000 parts as materials can often be sourced more cost effectively. In large series unit costs usually decrease only slightly and only minor optimizations remain.

For more information, see Cost Reduction in Thermoforming.

Cost Advantages of Thermoforming Compared to Other Processes

Thermoforming offers clear economic advantages:

• Lower tooling costs since tools are significantly cheaper than injection molding tools.

  (Read more in our article Injection Molding vs. Thermoforming)

• Less post processing since colored plastic sheets often eliminate the need for painting.
• Large parts from a single tool since sheets up to approximately 4,000 × 3,000 mm enable large thin walled parts.
• Economical even for small series since low tooling costs allow a cost efficient project start.
• Fast and cost effective prototyping since tools made from Ureol or 3D printing enable quick prototypes and sample parts.

High Scalability in Series Production

An often underestimated advantage of thermoforming is its long term scalability. Once the tool is available production can be scaled almost indefinitely. The initial tooling investment becomes less significant with each additional unit produced.

As a result costs per part continuously decrease with increasing production volume which makes the process especially attractive for projects that grow after market entry.

Conclusion

Thermoforming is an economically attractive process especially for projects that start with smaller series and later scale. Tooling costs are a one time and manageable investment and unit costs decrease significantly as production volume increases

Anyone who considers costs early and plans for volume growth can use thermoforming strategically and fully leverage its economic advantages. If you have further questions feel free to contact us. We are happy to help.