Cost Estimation

Estimate an FDM print quote by building it from four parts: variable per-part costs (material, consumables, packaging), time-based costs (machine time + labor), a failure/risk allowance, and overhead. Use slicer grams and time as inputs, but keep your quotes accurate by calibrating slicer time and typical waste with a few real prints per printer/profile.

TL;DR

Quote FDM prints by pricing slicer grams and print hours, then adding labor minutes, a waste/failure allowance, and overhead. Calibrate slicer time and real filament usage with 3–5 test jobs so you don’t undercharge on long prints or support-heavy parts.

Cost EstimationTopic-specific diagram for the concept, checks, and tradeoffs in this lesson.Slicer inputsgrams, hoursMaterialprice per kgElectricitywatts, kWhMachine rateper hourLaborsetup to packConsumablesnozzle, tools, adhesive},{
A compact cost-bucket diagram helps learners remember what to include and how the total is built from slicer inputs plus real-world rates.

What you are estimating (the 4 buckets)

A reliable quote is a total of: (1) variable costs that scale with each part, (2) time-based costs that scale with print time and handling time, (3) risk for failures/reprints, and (4) overhead and profit. The slicer gives you two key inputs (material mass and print time), but your shop-specific rates decide whether the quote is accurate and sustainable.

Cost buckets to include

  • Material: filament used plus typical purge/prime/waste
  • Machine time: hourly machine rate that covers depreciation and maintenance
  • Electricity: average watts during the print times your local kWh price
  • Labor: setup, starting the job, checks, removal, cleanup, support removal
  • Consumables: nozzle wear, bed surface/adhesive, tools, gloves, sandpaper
  • Post-processing: inserts, sanding, painting, smoothing, assembly
  • Packaging: bag/box, padding, label, paperwork
  • Overhead and admin: rent, software, bookkeeping, communication time, plus a failure allowance

Core formulas (per part)

Filament cost
(grams used / 1000) x material price per kg
Electricity cost
(avg watts / 1000) x hours x kWh price
Machine time cost
print hours x machine rate per hour
Labor cost
labor hours x labor rate per hour
Failure allowance
subtotal x failure rate (or add 1 extra part per N)

Setting rates that won’t surprise you later

Machine rate: estimate (printer purchase cost / expected lifetime print hours) and add a maintenance buffer for nozzles, belts, fans, beds, and downtime. Electricity: measure average power with a plug-in power meter on a typical PLA job and a typical high-temp job; many printers draw much more during heat-up than steady printing. Labor: time your own steps once (prep, load filament, start, first-layer check, removal, cleanup, packaging) and reuse those minutes by part category (easy, support-heavy, precision).

Quick estimating workflow (quote-ready)

  1. Slice using the exact profile you plan to print (layer height, walls, infill, supports). Record grams and print hours.
  2. Material: compute filament cost from grams; add a standard waste amount if you often purge, swap colors, or use brims/rafts.
  3. Machine time: multiply slicer hours by your machine rate; apply a time multiplier if that printer/profile runs slower than the slicer predicts.
  4. Electricity: multiply measured average watts by hours and by your kWh price (optional if you fold power into machine rate).
  5. Labor: add minutes for setup, first-layer confirmation, removal, support cleanup, and packaging.
  6. Add fixed consumables or post-processing line items (or convert them into labor minutes).
  7. Risk: apply a failure allowance based on similar jobs (tiny parts, tall thin parts, large flat parts, abrasive filaments, new material).
  8. Add overhead and profit margin as separate lines, then round to a clean number and set a minimum order/setup fee if needed.

When your quotes miss reality

Actual print time is much longer than the estimate

Likely cause: Acceleration/jerk limits, cooling slowdowns, minimum layer time, or max volumetric flow differs from the slicer assumptions

Fix: Run a timing calibration print per printer/profile and apply a time multiplier when quoting

Material usage is higher than expected

Likely cause: Extra purge, brim/raft use, filament swaps, retries, or support changes after quoting

Fix: Weigh the spool before/after several jobs and add a standard waste allowance (grams) per print or per material swap

Labor takes longer than planned

Likely cause: Support removal and surface cleanup dominate, or operator steps vary between prints

Fix: Create a standard work checklist and add labor minutes for support-heavy geometries and quality requirements

Profit disappears on small batches

Likely cause: Setup, communication, and packaging overhead dominates unit cost

Fix: Add a setup fee and minimum order price; apply quantity discounts only after overhead is covered