Foundry & Forging worked example

Forge Die Cost per Part at 110% tooling cost allocation: a worked example

What does the result look like when tooling cost allocation reaches 110%? The full calculation is worked below with real intermediate numbers. Use it when tooling life and die maintenance affect quote cost for closed-die forging, trimming, coining, or upset operations.

The inputs for this scenario

  • Forgings covered by the die cost: 12,000 parts (unchanged)
  • Die cost per covered part: 0.85 $ / part (unchanged)
  • Tooling cost allocation: 110 % (raised for this scenario; the documented default is 100)
  • Fixed die setup or repair cost: 2,500 $ (unchanged)

Working through the calculation

  • Applying the documented formula (Total forge die cost per part = forgings covered by the die cost × die cost per covered part × tooling cost allocation + fixed die setup or repair cost) to the inputs above produces each figure below.
  • At this operating point the engine returns 13,720 $ for total forge die cost per part, the number this scenario is built around.
  • At this operating point the engine returns 1.14 $ / piece for forge die cost per part.
  • At this operating point the engine returns 11,220 $ for variable forge die cost per part.
  • At this operating point the engine returns 2,500 $ for fixed die setup or repair cost.

How this compares with the baseline

  • Against the tool's baseline example, where tooling cost allocation sits at 100% and the headline result is 12,700 $, this scenario comes in 8.03% above the baseline at 13,720 $.
  • A figure at this level is achievable when tooling cost allocation is genuinely sustained, not just peaked for a shift. It assumes the die actually reaches the covered forging count; if die life falls short due to premature wear or breakage, the real cost per part rises because fixed costs spread over fewer pieces.

Results at a glance

  • Total forge die cost per part: 13,720 $ (headline result)
  • Forge die cost per part: 1.14 $ / piece
  • Variable forge die cost per part: 11,220 $
  • Fixed die setup or repair cost: 2,500 $

Run it with your numbers

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

Last reviewed 2026-05-12.