Tooling, Fixtures, Dies & Mold Economics worked example

Tool Life Cost at 99% wear-out realization: a worked example in tooling, fixtures, dies & mold economics

This scenario runs the tool life cost calculation on the strong side: 99% wear-out realization, with every other input held at its documented default. A machining cell estimates the cutting-tool spend baked into a long milling order before locking the per-part rate.

The inputs for this scenario

  • Tool replacements over the run: 40 tools (unchanged)
  • Purchase cost per tool: 85 $/tool (unchanged)
  • Wear-out realization: 99 % (raised for this scenario; the documented default is 90)
  • Regrind & setup adder: 250 $ (unchanged)

Working through the calculation

  • Applying the documented formula (Total tool life cost = replacements x cost per tool x wear-out realization% + regrind adder) to the inputs above produces each figure below.
  • At this operating point the engine returns 3,616 $ for total tool life cost, the number this scenario is built around.
  • At this operating point the engine returns 90.4 $ / piece for tool life cost per unit.
  • At this operating point the engine returns 3,366 $ for variable tool life cost.
  • At this operating point the engine returns 250 $ for fixed tool life cost adder.

How this compares with the baseline

  • Against the tool's baseline example, where wear-out realization sits at 90% and the headline result is 3,310 $, this scenario comes in 9.24% above the baseline at 3,616 $.
  • Use it when estimating perishable tooling cost for a quote, comparing tool grades or brands over a run, or sizing the tooling line on a job's cost sheet. 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

  • Total tool life cost: 3,616 $ (headline result)
  • Tool life cost per unit: 90.4 $ / piece
  • Variable tool life cost: 3,366 $
  • Fixed tool life cost adder: 250 $

Run it with your numbers

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

Last reviewed 2026-05-12.