Aluminum Extrusion & Profile Manufacturing worked example

Aluminum Extrusion Die Trial Cost at 110% trial cost recovery share: a worked example

This scenario runs the aluminum extrusion die trial cost calculation on the strong side: 110% trial cost recovery share, with every other input held at its documented default. a die designer or estimator needs to budget trial cost before launching a custom extrusion

The inputs for this scenario

  • Trial hours or billets run: 12 units (unchanged)
  • Cost per trial hour or billet: 650 $ / unit (unchanged)
  • Trial cost recovery share: 110 % (raised for this scenario; the documented default is 100)
  • Fixed engineering and setup cost: 2,200 $ (unchanged)

Working through the calculation

  • Applying the documented formula (Recovered variable trial cost = die trial hours or billets × cost per trial hour or billet × trial cost recovery share) to the inputs above produces each figure below.
  • At this operating point the engine returns 10,780 $ die trial cost for total die trial cost, the number this scenario is built around.
  • At this operating point the engine returns 898 $ / piece for cost per trial hour or billet.
  • At this operating point the engine returns 8,580 $ for recovered variable trial cost.
  • At this operating point the engine returns 2,200 $ for fixed engineering and setup cost.

How this compares with the baseline

  • Against the tool's baseline example, where trial cost recovery share sits at 100% and the headline result is 10,000 $ die trial cost, this scenario comes in 7.8% above the baseline at 10,780 $ die trial cost.
  • Use it when quoting a new die program or deciding whether to fund another correction trial on an existing die. Treat this as a target state: the delta against the baseline quantifies what the improvement is worth before you commit to chasing it.

Results at a glance

  • Total die trial cost: 10,780 $ die trial cost (headline result)
  • Cost per trial hour or billet: 898 $ / piece
  • Recovered variable trial cost: 8,580 $
  • Fixed engineering and setup cost: 2,200 $

Run it with your numbers

  • Every input above is editable in the live Aluminum Extrusion Die Trial Cost calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.