(MY)CAT4SLM© – A novel advanced SLM costing analysis tool for small and Medium-Sized Enterprises: Development, Implementation and Validation

As a prominent metal additive manufacturing technology, Selective Laser Melting (SLM) provides distinct opportunities for cost-effective and sustainable production, where the ability to fabricate complex geometries and lightweight components is critical. Nonetheless, accurately estimating the final cost remains a significant challenge due to the multitude of factors influencing the process. This study explores the development, implementation and validation of a novel costing analysis tool designed for products produced via SLM, universally termed as CAT4SLM, which is aimed at supporting small and medium-sized enterprises (SME) in navigating these complexities using a wide-accessible and cost-effective Excel-based analytical tool with macro capabilities. This tool adopts a mixed-methods approach combining qualitative insights from industry experts with quantitative data analysis, integrates major cost drivers and process parameters specific to SLM production and facilitates a comprehensive assessment of manufacturing costs and potential savings. Raw and recycled powder materials were incorporated as critical cost elements in this costing model, along with machine investment, maintenance and depreciation, labour expenses, consumables and indirect energy costs. The tool considers detailed production stages, such as pre-printing (part orientation, slicing, support structure generation), actual printing (warm-up, print and cool-down times) and post-processing operations (heat treatment, support removal and quality control) with process continuity using additional substrate plates to optimize production flow. A case project focusing on the Malaysian aerospace industry, specifically termed “(MY)CAT4SLM© Program”, demonstrates the tool’s application in analyzing the production of an aileron bracket. Comparative analysis with quotations from local Malaysian manufacturer validated the tool’s accuracy and practical applicability in the local market context. Results demonstrated strong agreement with 2.26% deviation compared to manufacturer quotations and significant economies of scale revealed cost reductions of more than 80% on serial production. This innovative costing model, adaptable to different production requirements and currency contexts, empowers SMEs to make informed strategic decisions, optimize resource allocation and achieve enhanced competitiveness through cost-effective adoption and utilization of SLM technology, specifically for low-volume-high-variation manufacturing scenarios.