Thermoforming & Vacuum Formed Products worked example

Formed Part Cost at 92% share of cost that is truly variable: a worked example

Push share of cost that is truly variable up to 92% and the picture changes. This example computes every intermediate figure at that operating point. Use it when formed part cost in thermoforming and vacuum formed products is being put through a thermoforming and vacuum formed products weighted-cost review.

The inputs for this scenario

  • Formed parts in the costed batch: 100 units (unchanged)
  • Variable cost per formed part: 45 $ / unit (unchanged)
  • Share of cost that is truly variable: 92 % (raised for this scenario; the documented default is 80)
  • Fixed setup and tooling amortization: 250 $ (unchanged)

Working through the calculation

  • Applying the documented formula (Formed 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 share of cost that is truly variable sits at 80% and the headline result is 3,850 $, this scenario comes in 14.03% above the baseline at 4,390 $.
  • It weights per-part variable cost by the truly-variable share, adds fixed setup and tooling, and divides by the batch to give cost per formed part. 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 Formed Part Cost calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.