Plating, Anodizing & Surface Treatment worked example

Anodizing Cost per Part at 99% first-pass acceptance rate: a worked example

What does the result look like when first-pass acceptance rate reaches 99%? The full calculation is worked below with real intermediate numbers. Use it when quoting aluminum anodizing to price the tank time, sealing, and rejects that each finished part actually absorbs.

The inputs for this scenario

  • Surface area anodized per part: 2.5 sq ft (unchanged)
  • Anodize price per square foot: 3.2 $/sq ft (unchanged)
  • First-pass acceptance rate: 99 % (raised for this scenario; the documented default is 96)
  • Seal and rack changeover adder: 1.5 $ (unchanged)

Working through the calculation

  • Applying the documented formula (Anodize cost = area x cost per square foot x acceptance% + seal and rack adder) to the inputs above produces each figure below.
  • At this operating point the engine returns 9.42 $ for total anodizing cost per part cost, the number this scenario is built around.
  • At this operating point the engine returns 3.77 $ / piece for anodizing cost per part cost per unit.
  • At this operating point the engine returns 7.92 $ for variable anodizing cost per part cost.
  • At this operating point the engine returns 1.5 $ for fixed anodizing cost per part adder.

How this compares with the baseline

  • Against the tool's baseline example, where first-pass acceptance rate sits at 96% and the headline result is 9.18 $, this scenario comes in 2.61% above the baseline at 9.42 $.
  • A figure at this level is achievable when first-pass acceptance rate is genuinely sustained, not just peaked for a shift. It models Type II/III shop pricing at a run level and does not break out masking labor, minimum-lot charges, or hazardous-waste surcharges that some job shops bill separately.

Results at a glance

  • Total anodizing cost per part cost: 9.42 $ (headline result)
  • Anodizing cost per part cost per unit: 3.77 $ / piece
  • Variable anodizing cost per part cost: 7.92 $
  • Fixed anodizing cost per part adder: 1.5 $

Run it with your numbers

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

Last reviewed 2026-05-12.