10 - Cost analysis

Abstract

Publisher Summary To illustrate different factors affecting the cost of textile composites, this chapter describes a cost modeling tool such that the process of cost estimation can be understood. It discusses cost build-up in textile composite applications, presenting a review of raw material prices. As the basis for examples presented throughout the chapter, it describes a cost prediction tool, which will drive an understanding of how cost is built-up in textile composite applications. This parametric Technical Cost Model (TCM) is based in MS Excel TM, interacting with MS Visual Basic TM. The TCM can be coupled with a discrete event-based Process-Flow Simulation (PFS) tool that dynamically represents the interactions between the different manufacturing operations. Hence, an averaging effect is gained over a statistically significant period, thereby generating input data for the TCM and increasing the accuracy of the cost calculation. The chapter also discusses the typical process machine and tooling costs, presents a summary of the effect of manufacturing volume on cost and the typical manufacturing volume of textile composite conversion processes. Assembly costs form important cost portions of a module and the chapter describes the effect of parts count reduction on cost. The chapter presents two case studies that show the build-up of system cost for components made of textile composite structures: (1) Chassis brace components produced by thermoplastic sheet stamping and over-injection molding and (2) Carbon epoxy aft fuselage panels for the Airbus A380.