Refined Cost Calculation Framework for FDM Parts

Fused deposition modeling (FDM) is a widely used additive manufacturing (AM) technology, favored for its design flexibility and suitability for low-volume production. However, precise cost estimation remains a critical challenge, particularly in industrial environments where decision-making depends on accurate financial assessments. This study proposes a comprehensive, parameter-based cost calculation model for FDM processes, with a special focus on the wear of machine tooling. Unlike conventional methods, the model separates tooling costs from general machine operation costs and introduces a novel approach to nozzle wear estimation based on extruded material volume rather than printing time. The framework incorporates key cost components—including material usage, support removal, machine operation, tooling degradation, and labor—and links them to quantifiable parameters such as part volume, build time, and energy consumption. The methodology was tested across multiple scenarios with different geometries and production volumes, revealing significant differences between time- and volume-based wear calculations. The results demonstrate that the proposed model provides more accurate and adaptable cost predictions, especially in varied production settings. This approach enhances the financial transparency of FDM workflows and supports better-informed decisions in both prototyping and small-batch manufacturing contexts.