Thermal Spray, Hardfacing & Wear Coatings worked example

Coated Part Cost at 92% deposit efficiency: a worked example

Push deposit efficiency up to 92% and the picture changes. This example computes every intermediate figure at that operating point. Use it when coated part cost in thermal spray, hardfacing and wear coatings is being put through a thermal spray, hardfacing and wear coatings weighted-cost review.

The inputs for this scenario

  • Parts coated in the batch: 100 units (unchanged)
  • Coating cost per part (consumables + labor + gas): 45 $ / unit (unchanged)
  • Deposit efficiency (usable coating vs. sprayed): 92 % (raised for this scenario; the documented default is 80)
  • Fixed batch setup cost (masking, fixturing, gun prep): 250 $ (unchanged)

Working through the calculation

  • Applying the documented formula (Coated Part Cost 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 deposit efficiency sits at 80% and the headline result is 3,850 $, this scenario comes in 14.03% above the baseline at 4,390 $.
  • It computes total batch coating cost as parts x per-part rate x deposit efficiency plus fixed setup, then divides by batch size for a per-part cost. The value of this scenario is the size of the gap it exposes: that gap, priced out over a year, is the budget you can justify spending to close it.

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 Coated Part Cost calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.