How many parts per cavity should a first article layout include?

The number your customer's requirement states. A first article usually covers the first part from the new process or a sample of the first batch. PPAP dimensional results usually report at least six pieces per product and process.

Why lay out a part from every cavity?

Because each cavity is cut separately, so a dimension can pass in one cavity and fail in another. One part from each cavity is the least that shows it.

How do I find my time per characteristic?

Divide the minutes a recent layout spent measuring, without programming or report time, by the characteristic checks it recorded. Use a part measured the same way, since a programmed CMM and hand gauges run at different speeds.

What happens to the cost if the first article fails?

You pay for another pass. The tool is corrected, the trial run repeated and at least the failed characteristics laid out again, so price each pass your tools usually need.

Injection Molding calculator

Mold First Article Cost Calculator

Price a first article or PPAP layout before you quote a new mold or an engineering change. You need the trial run cost, balloon count, parts laid out, time per characteristic, programming hours and quality labor rate.

What this calculator does

Cost of a mold's first article: the trial run, a full layout of every ballooned characteristic, and programming and report time.

Formula used

Characteristic checks = ballooned characteristics × parts laid out
Layout labor cost = checks × time per characteristic ÷ 60 × quality labor rate
Programming and report cost = programming and report hours × quality labor rate
First article cost = trial run cost + layout labor cost + programming and report cost
Cost of each extra part = characteristics × time per characteristic ÷ 60 × quality labor rate

Inputs explained

Trial Run Cost: Press time, resin and setup to mold the first-article shots.
Ballooned Characteristics: Count of numbered balloons on the ballooned drawing.
Parts Laid Out in Full: One per cavity for a first article; PPAP usually reports more.
Time per Characteristic: Measure and record one characteristic on one part, from past layouts.
Programming and Report Hours: CMM programming, ballooning and report assembly, once per part number.
Quality Labor Rate: Burdened hourly cost of the inspector or quality engineer.

How to use the result

Best suited to quoting FAI or PPAP on a new mold, re-quoting a layout after an engineering change, pricing a customer request for more parts.
A failed first article repeats the trial run and layout after tool correction; this prices one pass. Material certifications, lab tests and customer travel are not included.

Current U.S. benchmarks

As of Sep 2026, average hourly earnings in U.S. manufacturing are $30.21 (BLS), up 3.4% from a year earlier. Burdened shop rates typically run 1.3 to 1.8 times earnings once benefits and overhead are loaded.
The producer price index for plastic resins and materials stands at 280.569 (BLS, Aug 2026), up 6.6% from a year earlier. Quotes priced off last quarter's material cost miss this move.
The U.S. has 9,635 plastics product manufacturing establishments employing about 677,302 workers (Census County Business Patterns, 2023).

Common questions

How many parts per cavity should a first article layout include? The number your customer's requirement states. A first article usually covers the first part from the new process or a sample of the first batch. PPAP dimensional results usually report at least six pieces per product and process.
Why lay out a part from every cavity? Because each cavity is cut separately, so a dimension can pass in one cavity and fail in another. One part from each cavity is the least that shows it.
How do I find my time per characteristic? Divide the minutes a recent layout spent measuring, without programming or report time, by the characteristic checks it recorded. Use a part measured the same way, since a programmed CMM and hand gauges run at different speeds.
What happens to the cost if the first article fails? You pay for another pass. The tool is corrected, the trial run repeated and at least the failed characteristics laid out again, so price each pass your tools usually need.

Last reviewed 2026-10-02.