Precision Springs, Stampings & Micro-Formed Components worked example

Tooling Wear Cost at 99% wear-life consumed: a worked example

What does the result look like when wear-life consumed reaches 99%? The full calculation is worked below with real intermediate numbers. A tooling engineer allocating progressive-die wear to a job uses it to load amortized punch life into the piece price.

The inputs for this scenario

  • Parts stamped this run: 50,000 parts (unchanged)
  • Tool wear cost per part: 0.01 $/part (unchanged)
  • Wear-life consumed: 99 % (raised for this scenario; the documented default is 90)
  • Sharpening setup charge: 220 $ (unchanged)

Working through the calculation

  • Applying the documented formula (Tooling wear cost = parts stamped x wear cost per part x wear-life consumed% + sharpening charge) to the inputs above produces each figure below.
  • At this operating point the engine returns 814 $ for total tooling wear cost, the number this scenario is built around.
  • At this operating point the engine returns 0.02 $ / piece for tooling wear cost per unit.
  • At this operating point the engine returns 594 $ for variable tooling wear cost.
  • At this operating point the engine returns 220 $ for fixed tooling wear cost adder.

How this compares with the baseline

  • Against the tool's baseline example, where wear-life consumed sits at 90% and the headline result is 760 $, this scenario comes in 7.11% above the baseline at 814 $.
  • A figure at this level is achievable when wear-life consumed is genuinely sustained, not just peaked for a shift. It assumes a linear wear-cost model; real punch wear is often non-linear near end-of-life, so a die approaching the last 10% of its wear window can cost far more per part than the average implies.

Results at a glance

  • Total tooling wear cost: 814 $ (headline result)
  • Tooling wear cost per unit: 0.02 $ / piece
  • Variable tooling wear cost: 594 $
  • Fixed tooling wear cost adder: 220 $

Run it with your numbers

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

Last reviewed 2026-05-12.