Understand how a realistic 3D print failure rate changes the expected cost of each successful part. This model treats a failed attempt as consuming material and machine time, but not the finishing and packaging reserved for successful pieces.
Live Failed Print & Scrap Cost Calculator
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Calculation results
These are illustrative estimates, not guaranteed costs or fees. All money inputs must be expressed in the chosen denomination. The currency selector does not perform exchange-rate conversion.
If failures are independent and each unsuccessful attempt uses the same material and machine resources, expected attempts per success equal 1 ÷ (1 − failure probability). Apply that multiplier only to per-attempt expenses, then add finishing and packaging costs once for the completed part.
Worked example
A $5 print attempt with a 10% failure probability requires 1.111 expected attempts per success. That adds about $0.56 in risk allowance. With $2 finishing and $1 packaging, expected cost is $8.56 per good unit.
Common questions
Is this a guarantee about failed print quantities?
No. The result is an expected value across many jobs. Actual failures may be higher or lower.
What happens when a failure occurs after post-processing?
Add post-processing to the per-attempt cost instead of the per-good-unit amount if that labor is usually lost on failed items.
Does this include purge waste?
Only if included in material cost per attempt. Keep purge waste distinct from full failed-print probability to avoid double-counting.
How should I estimate my failure rate?
Count failed attempts over a representative series of production attempts. Separate material, machine, and design-related problems when possible.