Understanding these seven cost drivers allows your engineering or procurement team to optimise spend before sending a file for quote.
1. Print Technology
Technology selection is the single biggest cost lever. An FDM nylon jig and an SLS nylon jig made from identical material can differ in price by 5× due to process alone. Use FDM for non-cosmetic functional parts, SLS/MJF for production-grade nylon, and metal printing only where geometry or mechanical performance demands it.
2. Material Selection
Standard PLA and PETG cost A$20–A$30 per kg. Engineering materials — ABS-like resins, glass-filled nylon, carbon-fibre reinforced composites — cost A$70–A$150 per kg. Metal powders (316L stainless, titanium Ti64) can run to several hundred dollars per kilogram, which is reflected directly in per-part pricing.
3. Part Volume and Geometry
Pricing is typically tied to bounding box volume — the total space the part occupies in the build chamber — not just material weight. Tall, thin, or wide parts can cost more than denser compact geometries of equal mass. Hollowing internal sections and reducing wall thickness where structurally acceptable can reduce costs by 20–40%.
4. Layer Height and Resolution
Finer layer heights (e.g., 0.05 mm vs 0.2 mm) produce superior surface quality but increase print time significantly. For internal brackets or housings where surface finish is not critical, specifying a coarser resolution at the quoting stage is a straightforward cost reduction lever.
5. Support Structures and Orientation
Parts that require extensive support material use more raw material and add post-processing labour. Experienced DfAM (Design for Additive Manufacturing) engineers can often redesign features to reduce or eliminate supports — a consultation that frequently saves more than it costs.
6. Post-Processing and Finish
Standard finishing (support removal, sanding to Ra 3.2 µm) is typically included in the quote. Add-on services — painting, anodising, chrome plating, vapour smoothing, dyeing, and inspection reports — are charged additionally. For batch orders, post-processing can represent 30–50% of total job cost for high-finish requirements.
7. Order Quantity
Unit economics improve substantially with volume. A single SLS nylon part may cost A$400–A$600, whereas the same part in a batch of 50 can fall to A$150–A$200 per unit due to build-chamber packing efficiency and amortised setup. Industrial and commercial clients with recurring orders should discuss standing agreements or blanket purchase orders.
