Implantable Electronics & Neurodevices worked example

Encapsulation Scrap Cost at 54% encapsulation-attributed scrap share: a worked example

Here is what the math looks like when conditions slip. We hold every other input steady and drop encapsulation-attributed scrap share to 54%, then walk the calculation through step by step. Estimate the cost of scrapped implantable assemblies caused by encapsulation, potting, coating, or silicone overmold defects.

The inputs for this scenario

  • Affected encapsulated assemblies: 36 assemblies (held at the documented default)
  • Cost per scrapped assembly: 820 $ / assembly (held at the documented default)
  • Encapsulation-attributed scrap share: 54 % (the input this scenario stresses; the baseline uses 75)
  • Encapsulation cleanup and investigation cost: 2,200 $ (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Variable encapsulation scrap cost = affected encapsulated assemblies × cost per scrapped assembly × encapsulation-attributed scrap share.
  • Total encapsulation scrap cost works out to 18,141 $ at these inputs, and this is the headline figure for the scenario.
  • Encapsulation scrap cost per affected assembly works out to 504 $ / device at these inputs.
  • Variable encapsulation scrap cost works out to 15,941 $ at these inputs.
  • Encapsulation cleanup and investigation cost works out to 2,200 $ at these inputs.

How this compares with the baseline

  • Against the tool's baseline example, where encapsulation-attributed scrap share sits at 75% and the headline result is 24,340 $, this scenario comes in 25.47% below the baseline at 18,141 $.
  • The practical read: the gap between this scenario and the baseline is entirely attributable to encapsulation-attributed scrap share, so recovering it is worth quantifying in dollars before considering equipment or staffing changes. The attributed scrap share is a judgment call; if some failures share root cause with upstream steps, splitting cost cleanly between encapsulation and other processes is imperfect.

Results at a glance

  • Total encapsulation scrap cost: 18,141 $ (headline result)
  • Encapsulation scrap cost per affected assembly: 504 $ / device
  • Variable encapsulation scrap cost: 15,941 $
  • Encapsulation cleanup and investigation cost: 2,200 $

Run it with your numbers

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

Last reviewed 2026-05-12.