How do you calculate custom case turnaround cost?

Multiply the number of cases by the variable cost per case, then add fixed rush or setup cost and any extra labor and overhead. For 100 cases at $2.50 each plus $75 setup and $25 overhead, the total is $350.

What is the cost per custom case in this example?

$3.50 per case — the $350 total divided across 100 cases. That figure is what you compare against the rush surcharge you charge the dentist.

Why are rush and setup costs separated from the per-case cost?

Rush fees and setup are fixed regardless of batch size, so spreading them over more cases lowers the per-case figure. Here $100 of fixed adders ($75 setup + $25 overhead) dominate the $250 of variable workflow cost on a small batch.

Should overtime be in the variable cost or the overhead field?

Put scheduled overtime tied to the rush batch in the additional labor and overhead field. Keep the variable cost per case reflecting normal-shift consumables and machine time so your baseline stays clean.

How do I use this to price a rush surcharge?

Compare your loaded cost per case ($3.50 here) against your standard cost per case; the difference is the floor for your rush surcharge. Add margin on top rather than charging the raw incremental cost.

What is a good turnaround cost per case?

There is no universal benchmark — it depends on case type — but the rush premium should typically stay under 15-25% above your standard loaded cost per case, or dentists will route urgent work elsewhere.

Dental, Orthodontic & Prosthetics Manufacturing calculator

Custom Case Turnaround Cost Calculator

Custom case turnaround cost tells a dental or prosthetics lab what it actually costs to push a batch of custom cases through the workflow — crowns, aligners, dentures, or implant bars — from impression intake to ready-to-ship. It rolls the per-case variable cost together with one-off rush or setup charges and the labor and overhead burden that rush turnaround adds. Lab managers and case schedulers use it to price expedited orders and to decide whether a same-day or next-day commitment is worth taking. Because turnaround promises are how labs win and lose dentist accounts, knowing the true loaded cost per case is what separates a profitable rush program from a money-losing one.

What this calculator does

Estimate the cost of delivering custom dental, orthodontic, or prosthetic cases through scan review, design, fabrication, finishing, inspection, and shipment.
Use it when custom case turnaround cost in dental, orthodontic and prosthetics manufacturing is being quoted and you need a number you can defend on a phone call.
It computes the total cost of turning around a batch of custom cases plus the loaded cost per individual case.

Formula used

Total custom case turnaround cost = custom cases in scope × variable turnaround cost per case + fixed rush or setup cost + additional turnaround labor and overhead
Cost per custom case = total custom case turnaround cost ÷ custom cases in scope

Inputs explained

Custom cases in scope:
Variable turnaround cost per case:
Fixed rush or setup cost:
Additional turnaround labor and overhead:

How to use the result

Use it when quoting expedited or rush orders, evaluating a new turnaround SLA, or comparing a rush batch against a standard-lead-time run.
It assumes a single blended variable cost per case; mixed case types (a zirconia crown vs a flexible partial) have very different real costs and should be costed separately.

Current U.S. benchmarks

U.S. manufacturing runs at 75.6% of capacity with new factory orders at $657B per month (Federal Reserve and Census, May 2026).
The U.S. has 8,825 medical equipment and supplies establishments employing about 308,388 workers (Census County Business Patterns, 2023).

Common questions

How do you calculate custom case turnaround cost? Multiply the number of cases by the variable cost per case, then add fixed rush or setup cost and any extra labor and overhead. For 100 cases at $2.50 each plus $75 setup and $25 overhead, the total is $350.
What is the cost per custom case in this example? $3.50 per case — the $350 total divided across 100 cases. That figure is what you compare against the rush surcharge you charge the dentist.
Why are rush and setup costs separated from the per-case cost? Rush fees and setup are fixed regardless of batch size, so spreading them over more cases lowers the per-case figure. Here $100 of fixed adders ($75 setup + $25 overhead) dominate the $250 of variable workflow cost on a small batch.
Should overtime be in the variable cost or the overhead field? Put scheduled overtime tied to the rush batch in the additional labor and overhead field. Keep the variable cost per case reflecting normal-shift consumables and machine time so your baseline stays clean.
How do I use this to price a rush surcharge? Compare your loaded cost per case ($3.50 here) against your standard cost per case; the difference is the floor for your rush surcharge. Add margin on top rather than charging the raw incremental cost.

Last reviewed 2026-05-12.