Logan's project was ultimately to help Prusa Research evaluate its 3D printing manufacturing mode and investigate injection molding as a replacement manufacturing technology for the current production scale. To do so, Logan needed to build a cost model for the print farm. The first principle, Logan determined, was that only costs that differ between 3D printing and injection molding should be considered, namely the capital expense (CapEx), material, energy and direct labor for manufacturing the plastic parts in a printer kit. On the other hand, procurement of other parts, inspection, sorting and packaging, management, R&D, marketing, and shipping are not to be included because the same costs would still be incurred even if all plastic parts were injection-molded. Logan also estimated the facility cost (e.g., rent for the space for production), but found it to be magnitudes lower than other types of costs and negligible.Logan considered the information he had collected. As of February 2018, the print farm had 300 printers working 24/7 to ship 6,000 printers monthly. The Prusa i3 printers retail for about $1,000 each (assembled), although the production cost for each farm printer must be a lot less. Logan felt that a 65% gross margin should be in the ball park, so that he could assume that each farm printer costs Prusa Research $350. Joseph had said that it takes slightly more than one full day for a printer to print all plastic parts of a new printer. The productivity can be estimated in another way: 6,000 printers shipped monthly means that 300 printers on the farm produce 200 printers in 24 hours, which translates into a printer printing another printer's plastic parts in 1.5 days. The calculated productivity seems lower than what Joseph had said, but the difference may well be explained by overheads such as loading materials, removing finished parts, and other occasional downtime. Logan learned that farm printers on average last two years, which was rather impressive given that they work 24/7.The Prusa i3 printer has an average printing power consumption of 100 watts (W). The energy cost in the Czech Republic is $0.2/kilowatt hour (kWh). The raw material for production is Polyethylene Terephthalate Glycol (PETG) 3D printing filament, which costs $14 per kilogram (kg). Each Prusa i3 contains about 50 plastic parts weighing 0.5kg in total, all of which are currently 3D-printed. The parts are arranged to be printed in batches tightly occupying the entire printing bed so as to reduce human intervention. The printing process can be sloweasily taking more than 10 hours to finish full bed of partswhich is good news for the 15 employees tending to the print farm: they can schedule long print jobs overnight and work regular 8 hour shifts even though the print farm runs around the clock. Logan also learned that the 15 employees work 5-day shifts to cover all seven days of the week, and estimated a $15 hourly wage for them

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3D printing cost model CAPEX Cost of a farm printer ($) Lifespan (years) Cycle time (days/unit) Average cost ($/unit) MATERIAL PETG cost ($/kg) PETG usage (kg/unit) Average cost ($/unit) ENERGY Power (W) Energy usage (kWh/unit) Energy cost ($/kWh) Average cost ($/unit) LABOR Staff Wage ($/hr) Hours per day Days per week Weekly total cost ($) Weekly output Average cost ($/unit) Total unit cost ($/unit) 3D printing cost model CAPEX Cost of a farm printer ($) Lifespan (years) Cycle time (days/unit) Average cost ($/unit) MATERIAL PETG cost ($/kg) PETG usage (kg/unit) Average cost ($/unit) ENERGY Power (W) Energy usage (kWh/unit) Energy cost ($/kWh) Average cost ($/unit) LABOR Staff Wage ($/hr) Hours per day Days per week Weekly total cost ($) Weekly output Average cost ($/unit) Total unit cost ($/unit)