The PDMA Handbook of New Product Development

27.7. Costs and Staffing

Most of the high-end rapid prototyping machines will start around $ 180,000 and can cost as much as $750,000 for the largest machines. Concept modelers start around $30,000 and run up to $80,000. The cost of producing parts ranges from $0.70 per cubic inch and can go up to $3.50 per cubic inch. Most companies already have surface or solid model CAD systems, which is a requirement for rapid prototyping. Files sent to a rapid prototyping machine must be originated in 3-D. Maintenance on the laser systems requires that the laser be replaced at the 5000-7000 hour intervals along with power supply and diodes. The cost for this can be in the $26,000 range and should be budgeted in operation costs. Most concept modeler machines have small consumable replacement costs for items such as printer heads.

All rapid prototyping machines require a small amount of time to train staff, usually when the machine is delivered. Though the new machine can be up and running in a very short time, an operator's skills still need to be developed. Part orientation and STL file verification will take time to master in order to produce the highest-quality parts. Although it is possible to have all 3-D CAD people trained to run the rapid prototyping machine, it may be best to have two or three people handle these responsibilities exclusively. Not only does this allow them a sense of pride and ownership, but they will also learn from each other. These key people should join one of the ...