Gaskets, Seals, O-Rings & Elastomer Components worked example

Flash Scrap Cost at 72% scrap cost capture share: a worked example

This worked example runs the flash scrap cost numbers for a tougher week than the baseline: 72% scrap cost capture share instead of the typical 100%. Estimate the material cost of flash, trim, runner, and excess elastomer scrap from molded gasket and seal production.

The inputs for this scenario

  • Molded parts with flash scrap: 5,200 parts (held at the documented default)
  • Flash and trim scrap cost per part: 0.18 $ / part (held at the documented default)
  • Scrap cost capture share: 72 % (the input this scenario stresses; the baseline uses 100)
  • Fixed scrap handling cost: 275 $ (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Variable flash scrap cost = molded parts with flash scrap × flash and trim scrap cost per part × scrap cost capture share.
  • Total flash scrap cost works out to 949 $ at these inputs, and this is the headline figure for the scenario.
  • Flash scrap cost per molded part works out to 0.18 $ / piece at these inputs.
  • Variable flash scrap cost works out to 674 $ at these inputs.
  • Fixed scrap handling cost works out to 275 $ at these inputs.

How this compares with the baseline

  • Against the tool's baseline example, where scrap cost capture share sits at 100% and the headline result is 1,211 $, this scenario comes in 21.64% below the baseline at 949 $.
  • Use it when quoting a new molded seal, comparing deflash methods, or building the cost case for tooling rework that would reduce flash. A result at this level usually justifies acting on the stressed input before touching anything else, because every other figure in the table is downstream of it.

Results at a glance

  • Total flash scrap cost: 949 $ (headline result)
  • Flash scrap cost per molded part: 0.18 $ / piece
  • Variable flash scrap cost: 674 $
  • Fixed scrap handling cost: 275 $

Run it with your numbers

  • To rerun this with your own numbers, open the live Flash Scrap Cost calculator, set scrap cost capture share to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.