Thermoforming & Vacuum Formed Products worked example

Plastic Sheet Cost at 92% sheet-to-part yield factor: a worked example

This scenario runs the plastic sheet cost calculation on the strong side: 92% sheet-to-part yield factor, with every other input held at its documented default. Use it when plastic sheet 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

  • Parts formed from the sheet order: 100 units (unchanged)
  • Sheet material cost per part: 45 $ / unit (unchanged)
  • Sheet-to-part yield factor: 92 % (raised for this scenario; the documented default is 80)
  • Fixed setup and trim-die cost: 250 $ (unchanged)

Working through the calculation

  • Applying the documented formula (Plastic Sheet 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 sheet-to-part yield factor sits at 80% and the headline result is 3,850 $, this scenario comes in 14.03% above the baseline at 4,390 $.
  • Use it when quoting a run, comparing sheet suppliers or gauges, or testing whether a yield improvement changes piece price enough to matter. Treat this as a target state: the delta against the baseline quantifies what the improvement is worth before you commit to chasing 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 Plastic Sheet Cost calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.