Foundry & Forging calculator

Foundry Scrap Cost Calculator

Estimate the cost impact of scrap castings, rejected forgings, failed molds, bad cores, or nonconforming heat lots. Use it when scrap affects quote margin, production cost, root-cause priority, or customer recovery for a casting or forging program.

What this calculator does

  • Estimate the cost impact of scrap castings, rejected forgings, failed molds, bad cores, or nonconforming heat lots.
  • Use it when scrap affects quote margin, production cost, root-cause priority, or customer recovery for a casting or forging program.
  • Costs rejected foundry or forging output.

Formula used

  • Total foundry scrap cost = scrapped castings or forgings × cost per scrapped unit × scrap cost allocation + fixed containment or disposal cost
  • Scrap cost per rejected unit = total cost ÷ scrapped castings or forgings

Inputs explained

  • Scrapped castings or forgings: Enter rejected pieces, scrap weight units, bad molds, failed cores, or lots included in the estimate.
  • Cost per scrapped unit: Use metal, mold/core, melt, labor, machining, heat treat, inspection, and overhead cost per rejected unit.
  • Scrap cost allocation: Enter the share assigned to this part, customer, heat, supplier, or corrective-action case.
  • Fixed containment or disposal cost: Add sorting, lab testing, rework setup, disposal, customer chargeback, or expedited replacement cost.

How to use the result

  • Use for quality, finance, and production review.
  • This calculator is an estimating tool. Results can change with alloy chemistry, furnace practice, ladle losses, mold design, gating and riser layout, core condition, pattern allowance, die temperature, press condition, inspection criteria, rework rules, energy rates, labor standards, and actual shop performance. Validate safety-critical, metallurgical, tooling, press-capacity, and customer-spec decisions with qualified engineering, metallurgy, OEM data, and the applicable control plan.

Common questions

  • What information do I need before using the Foundry Scrap Cost? Use scrap count or weight, cost per unit, allocation percentage, and fixed containment cost.
  • What does the result mean? It estimates total scrap cost and cost per scrapped unit.
  • When is the result only an estimate? This calculator is an estimating tool. Results can change with alloy chemistry, furnace practice, ladle losses, mold design, gating and riser layout, core condition, pattern allowance, die temperature, press condition, inspection criteria, rework rules, energy rates, labor standards, and actual shop performance. Validate safety-critical, metallurgical, tooling, press-capacity, and customer-spec decisions with qualified engineering, metallurgy, OEM data, and the applicable control plan.
  • What decision can I make from the result? Use it to prioritize quality issues, update quotes, calculate COPQ, or support corrective action.

Last reviewed 2026-05-12.