Pultrusion & Continuous Composite Profiles worked example

Fiber Cost Per Foot at 92% fiber utilization: a worked example

What does the result look like when fiber utilization reaches 92%? The full calculation is worked below with real intermediate numbers. Use it when fiber cost per foot in pultrusion and continuous composite profiles is being put through a pultrusion and continuous composite profiles weighted-cost review.

The inputs for this scenario

  • Linear feet of profile pulled: 100 units (unchanged)
  • Roving and mat cost per foot: 45 $ / unit (unchanged)
  • Fiber utilization (net of scrap): 92 % (raised for this scenario; the documented default is 80)
  • Creel setup and waste allowance: 250 $ (unchanged)

Working through the calculation

  • Applying the documented formula (Fiber Cost Per Foot cost = quantity × rate × capture factor + fixed cost) to the inputs above produces each figure below.
  • At this operating point the engine returns 4,390 $ for weighted cost, the number this scenario is built around.
  • At this operating point the engine returns 43.9 $ / piece for per piece value.
  • At this operating point the engine returns 4,140 $ for captured value.
  • At this operating point the engine returns 250 $ for fixed adjustment.

How this compares with the baseline

  • Against the tool's baseline example, where fiber utilization sits at 80% and the headline result is 3,850 $, this scenario comes in 14.03% above the baseline at 4,390 $.
  • A figure at this level is achievable when fiber utilization is genuinely sustained, not just peaked for a shift. It treats fiber utilization as a single blended factor; it does not separately account for reinforcement architecture differences (rovings vs. continuous strand mat vs. surfacing veil), which carry different unit costs and waste rates.

Results at a glance

  • Weighted cost: 4,390 $ (headline result)
  • Per piece value: 43.9 $ / piece
  • Captured value: 4,140 $
  • Fixed adjustment: 250 $

Run it with your numbers

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

Last reviewed 2026-05-12.