An economic analysis comparing the cost feasibility of replacing injection molding processes with emerging additive manufacturing techniques

Additive manufacturing (AM) has proliferated in recent years and is displacing traditional manufacturing methods in numerous applications due to improvements in process efficiencies and cost reductions related to the evolving AM processes. This study explores the cost structure and break-even points of AM versus traditional methods. The comparative analysis examined the cost requirements of AM versus injection molding to manufacture various lot sizes of parts. Break-even points based on lot sizes and the relationship to the overall cost structure were also calculated. This research concludes that break-even points may be calculated based on part mass, density, and lot size.