Life Cycle Costing of new generation of molds for microinjection molding process

The growing need for flexibility and sustainability in industrial production has made it necessary to evaluate new strategies for the design and manufacture of molds for injection molding, especially for low-volume production. This study proposes a Life Cycle Costing (LCC) model to compare two micro-injection mold configurations: a conventional one (CIM) and a topologically optimised one (TOIM). The model considers three main stages of the life cycle: production, use and end of life, integrating economic, technical and energy parameters. The results show that, for limited batches (e.g., 200 pieces), the conventional mold is more advantageous in terms of cost per piece €15.85, compared to €17.43 (-9%). However, as production increases, the gap between the two solutions narrows significantly, making TOIM competitive due to its greater structural efficiency and lower weight. Furthermore, the parametric model developed allows the analysis to be adapted to different production scenarios and mold configurations. Although CIM remains more economical in most cases, TOIM represents a strategic solution for sustainable and technologically advanced production. The work provides a useful decision-making tool for selecting the most suitable solution based on economic and environmental objectives.