Additive Manufacturing worked example

Print Failure Cost with failed prints or builds of 2 failures: a worked example

Here is what the math looks like when conditions slip. We hold every other input steady and drop failed prints or builds to 2 failures, then walk the calculation through step by step. Estimate cost exposure from failed additive builds or rejected parts, including material, labor, and overhead recovery.

The inputs for this scenario

  • Failed prints or builds: 2 failures (the input this scenario stresses; the baseline uses 4)
  • Cost per failed print: 185 $ / failure (held at the documented default)
  • Recovery labor/setup: 220 $ (held at the documented default)
  • Failure overhead burden: 140 $ (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Failed print cost = failed prints × cost per failed print.
  • Total failure cost works out to 730 $ at these inputs, and this is the headline figure for the scenario.
  • Failure cost per print works out to 365 $ / failure at these inputs.
  • Failed print cost works out to 370 $ at these inputs.
  • Recovery and overhead burden works out to 360 $ at these inputs.

How this compares with the baseline

  • Against the tool's baseline example, where failed prints or builds sits at 4 failures and the headline result is 1,100 $, this scenario comes in 33.64% below the baseline at 730 $.
  • The practical read: the gap between this scenario and the baseline is entirely attributable to failed prints or builds, so recovering it is worth quantifying in dollars before considering equipment or staffing changes. It treats cost per failed print as an average; a failure deep into a long build wastes far more than an early one, so segment by build stage for precision.

Results at a glance

  • Total failure cost: 730 $ (headline result)
  • Failure cost per print: 365 $ / failure
  • Failed print cost: 370 $
  • Recovery and overhead burden: 360 $

Run it with your numbers

  • To rerun this with your own numbers, open the live Print Failure Cost calculator, set failed prints or builds to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.