Thermal Spray, Hardfacing & Wear Coatings worked example

Coated Part Cost at 58% deposit efficiency: a worked example

This worked example runs the coated part cost numbers for a tougher week than the baseline: 58% deposit efficiency instead of the typical 80%. Coated Part Cost tells a thermal spray shop what it truly costs to apply a wear-resistant coating to a batch of parts, blending variable coating cost per part, a deposit-efficiency factor, and the fixed setup burden of masking and fixturing.

The inputs for this scenario

  • Parts coated in the batch: 100 units (held at the documented default)
  • Coating cost per part (consumables + labor + gas): 45 $ / unit (held at the documented default)
  • Deposit efficiency (usable coating vs. sprayed): 58 % (the input this scenario stresses; the baseline uses 80)
  • Fixed batch setup cost (masking, fixturing, gun prep): 250 $ (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Coated Part Cost cost = quantity × rate × capture factor + fixed cost.
  • Weighted cost works out to 2,860 $ at these inputs, and this is the headline figure for the scenario.
  • Per piece value works out to 28.6 $ / piece at these inputs.
  • Captured value works out to 2,610 $ at these inputs.
  • Fixed adjustment works out to 250 $ at these inputs.

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 25.71% below the baseline at 2,860 $.
  • Use it when quoting a coating job or reviewing whether an existing HVOF, plasma, or arc-spray line is priced to cover powder waste and setup. A result at this level usually justifies acting on the stressed input before touching anything else, because every other figure in the table is downstream of it.

Results at a glance

  • Weighted cost: 2,860 $ (headline result)
  • Per piece value: 28.6 $ / piece
  • Captured value: 2,610 $
  • Fixed adjustment: 250 $

Run it with your numbers

  • To rerun this with your own numbers, open the live Coated Part Cost calculator, set deposit efficiency to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.