PLM, BOM & Digital Thread worked example

CAD Library Duplication Cost at 86% confirmed redundant copies: a worked example

What does the result look like when confirmed redundant copies reaches 86%? The full calculation is worked below with real intermediate numbers. Use it to justify a geometric-search de-duplication effort by sizing the cost of redundant CAD files.

The inputs for this scenario

  • Duplicated CAD models in the library: 900 models (unchanged)
  • Storage and maintenance cost per model: 22 $/model/yr (unchanged)
  • Confirmed redundant copies: 86 % (raised for this scenario; the documented default is 75)
  • De-duplication tooling cost: 5,000 $ (unchanged)

Working through the calculation

  • Applying the documented formula (Total cost = duplicated models x maintenance cost x redundant share + de-dup tooling) to the inputs above produces each figure below.
  • At this operating point the engine returns 22,028 $ for total cad library duplication cost, the number this scenario is built around.
  • At this operating point the engine returns 24.48 $ / piece for cad library duplication cost per unit.
  • At this operating point the engine returns 17,028 $ for variable cad library duplication cost.
  • At this operating point the engine returns 5,000 $ for fixed cad library duplication cost adder.

How this compares with the baseline

  • Against the tool's baseline example, where confirmed redundant copies sits at 75% and the headline result is 19,850 $, this scenario comes in 10.97% above the baseline at 22,028 $.
  • A figure at this level is achievable when confirmed redundant copies is genuinely sustained, not just peaked for a shift. Per-model maintenance cost captures storage and upkeep but not the harder-to-quantify cost of an engineer reusing a stale duplicate, which is often the larger loss.

Results at a glance

  • Total cad library duplication cost: 22,028 $ (headline result)
  • Cad library duplication cost per unit: 24.48 $ / piece
  • Variable cad library duplication cost: 17,028 $
  • Fixed cad library duplication cost adder: 5,000 $

Run it with your numbers

  • Every input above is editable in the live CAD Library Duplication Cost calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.