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The next example will demonstrate the plastic injection mold cost estimator. The top portion of a wireless computing terminal will be used as a case study. Select the “Sample Part” library from the main button panel, select “Infopad Case,” and click submit. Here is a picture of the infopad casing:

The complete set of facet specifications now in the MAS are:

• Batch Size = 200
• Shape = Freeform Drape
• Minimum Wall Thickness = 0.1 inches
• Maximum Wall Thickness = 0.15
• Wall Web Span = 3 inches
• Bounding Box Volume = 50 cubic inches
• Cost Per Part = Low Setup
• Cost = Medium
• Surface Roughness = 200 microinches
• Dimensional Tolerance = +/- 25 mils
• Cost Per Pound = $2.5 per pound (Material)
• Density = 150 pounds per cubic foot (Material)

Click on “Results Survey,” select the highest rank combination, and click “Cost Estimate.” The projected area of the part normal to the assumed parting plane was roughly 59 inch^2, the draw height 0.6 inches and the volume of the part (not the bounding box, but actual material) is estimated at 8.8 cubic inches. This data is entered on the first line of the estimator window. Note that the hole for the screen does not contribute to the projected area. The inner surface of the part is fairly complicated with a total of 50 surface patches and 12 holes.

The bulk of these surfaces are generated because of the numerous posts shown in (A). The outer surface only has 11 surfaces (small blending surfaces don’t count) and no holes. One internal core is needed for the slot at (B). The part is mainly planar, so the parting option is left at “Flat Parting Plane.” No special texture or embossing is needed, so the texturing is left alone.

Clicking on "Calc Results" yields these results:

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