Wearable Medical Sensors worked example

Sterilization Option Cost at 69% cycles needing full validation: a worked example

This scenario runs the sterilization option cost calculation on the strong side: 69% cycles needing full validation, with every other input held at its documented default. A quoting engineer comparing ethylene oxide versus e-beam sterilization spend for a sensor's annual build volume.

The inputs for this scenario

  • Sterilization Lot Cycles: 40 cycles (unchanged)
  • Per-Cycle Processing Charge: 850 $ / cycle (unchanged)
  • Cycles Needing Full Validation: 69 % (raised for this scenario; the documented default is 60)
  • Cycle Development & Dosimetry Setup: 9,000 $ (unchanged)

Working through the calculation

  • Applying the documented formula (Total sterilization cost = lot cycles x per-cycle charge x (% validated) + setup) to the inputs above produces each figure below.
  • At this operating point the engine returns 32,460 $ for total sterilization option cost, the number this scenario is built around.
  • At this operating point the engine returns 812 $ / piece for sterilization option cost per unit.
  • At this operating point the engine returns 23,460 $ for variable sterilization option cost.
  • At this operating point the engine returns 9,000 $ for fixed sterilization option cost adder.

How this compares with the baseline

  • Against the tool's baseline example, where cycles needing full validation sits at 60% and the headline result is 29,400 $, this scenario comes in 10.41% above the baseline at 32,460 $.
  • Use it when scoping a sterile SKU, negotiating a contract-sterilizer agreement, or building the validation budget for a new adhesive-electrode or skin-contact sensor. 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 sterilization option cost: 32,460 $ (headline result)
  • Sterilization option cost per unit: 812 $ / piece
  • Variable sterilization option cost: 23,460 $
  • Fixed sterilization option cost adder: 9,000 $

Run it with your numbers

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

Last reviewed 2026-05-12.