Fitness Equipment & Connected Exercise Hardware worked example

Frame Fabrication Cost at 110% allocated frame-cost share: a worked example

What does the result look like when allocated frame-cost share reaches 110%? The full calculation is worked below with real intermediate numbers. Use it when quoting welded, bent, machined, powder-coated, or purchased fitness equipment frames before launch or production release.

The inputs for this scenario

  • Fitness equipment frames in scope: 180 frames (unchanged)
  • Fabricated frame cost per unit: 145 $ / frame (unchanged)
  • Allocated frame-cost share: 110 % (raised for this scenario; the documented default is 100)
  • Fixed tooling, fixture, or coating setup cost: 1,250 $ (unchanged)

Working through the calculation

  • Applying the documented formula (Variable frame fabrication cost = fitness equipment frames in scope × fabricated frame cost per unit × allocated frame-cost share) to the inputs above produces each figure below.
  • At this operating point the engine returns 29,960 $ for total frame fabrication cost, the number this scenario is built around.
  • At this operating point the engine returns 166 $ / frame for average frame fabrication cost per unit.
  • At this operating point the engine returns 28,710 $ for variable frame fabrication cost.
  • At this operating point the engine returns 1,250 $ for fixed tooling, fixture, or coating setup cost.

How this compares with the baseline

  • Against the tool's baseline example, where allocated frame-cost share sits at 100% and the headline result is 27,350 $, this scenario comes in 9.54% above the baseline at 29,960 $.
  • A figure at this level is achievable when allocated frame-cost share is genuinely sustained, not just peaked for a shift. It uses one blended per-frame cost, so mixing frame types — a rack upright and a bike frame — in a single run will misstate both unless you cost them separately.

Results at a glance

  • Total frame fabrication cost: 29,960 $ (headline result)
  • Average frame fabrication cost per unit: 166 $ / frame
  • Variable frame fabrication cost: 28,710 $
  • Fixed tooling, fixture, or coating setup cost: 1,250 $

Run it with your numbers

  • Every input above is editable in the live Frame Fabrication Cost calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.