Omni3D lays out how to count cost per accepted part in small-series AM

Omni3D, a Polish maker of FFF and metal LPBF systems, has published a guide to lowering cost per part in small-series additive production, ahead of its IMTS 2026 appearance in Chicago. The core advice is to measure cost and throughput per accepted part across the whole workflow, not per build. The text also covers flow limits, supports, qualification and trial design.

Context FFF (fused filament fabrication) is a material extrusion process that builds parts by laying down molten thermoplastic filament layer by layer.

How should cost per part be calculated?

Omni3D proposes a batch-level formula: total production cost divided by the number of accepted parts. The cost base should include engineering and setup, structural, support and purge material, machine time, labour, post-processing, inspection and rejected builds. Reusable engineering work is spread over a realistic quantity, and the accounting boundary must stay the same when comparing FFF with machining or molding. A faster build can still cost more if it needs extra finishing or yields fewer good parts.

Flow, thermal control and supports

Higher programmed print speed does not raise deposition if the hotend cannot melt enough polymer. Omni3D advises checking the sliced toolpath to see whether volumetric flow is the real limit, and comparing settings on the same material, geometry and acceptance criteria. The Omni PRO HT has a heated chamber rated to 220°C and a head temperature up to 500°C, which the company says does not by itself validate a flow rate or mechanical performance for any filament grade. For dual extrusion, its ABS tooling case with ODS-20 soluble supports is an example, not proof for other polymers. Total support cost should include material, tool changes, purge, removal labour and washing equipment.

Metal, qualification and trial design

The Omni M280 LPBF system offers a 280 × 280 × 500 mm build volume with one 500 W laser, and two or four lasers as options. Omni3D holds NCAGE code 9BT1H, which it notes identifies the company but certifies no printer or part. For demanding uses, the text says to link design revision, material batch, printer configuration, build settings, post-processing and inspection records. Trials should use a representative part and fixed batch size, measure accepted parts per elapsed time, and test the ROI model against lower utilisation and yield.

What it means

The useful point for small and mid sized manufacturers is the accounting discipline: counting accepted parts, with rejects, finishing and inspection inside the boundary, is what makes an FFF to machining comparison honest. The text is vendor material ahead of a trade show, so machine specifications are capabilities, not validated results for a given material. Qualification evidence, training and auxiliary equipment still need budget and time before any batch is scaled.

Frequently asked questions

How does Omni3D define cost per accepted part?

Total batch production cost divided by the number of accepted parts, including engineering, materials, machine time, labour, post-processing, inspection and rejected builds.

Does a high printer temperature rating validate a material?

No. Omni3D states that the 220°C chamber and 500°C head ratings of the Omni PRO HT do not establish validated flow rates, supports or mechanical performance for every filament grade.

What does the NCAGE code mean?

Omni3D's code 9BT1H identifies the company within the NATO Codification System. The text says it does not certify the performance of a printer or printed part.