What Proportion of Total Cost Does the Mold Cost of Hollowed UHPC Shapes Account For? Cost Composition and Optimization Strategies

The mold cost share of openwork UHPC shapes is influenced by factors such as the openwork ratio, shape complexity, and production batch size, typically accounting for 15%-25% of the total cost, and may rise to 30%-40% for highly complex shapes. Based on project data such as the Ouargla Hotel in Algeria (50% openwork ratio) and the Shanghai Pop Mart commercial space, Qinglong Group has optimized the mold cost share to within 20% through standardized design, mold reuse, and process innovation, achieving a balance between economy and artistry.

Mold costs consist of material costs, machining costs, and trial molding costs. Openwork molds have a small effective area and low material utilization, and require more supporting structures to prevent deformation. CNC machining takes a long time, with work hours for five-axis CNC engraving of complex patterns increasing by 50%-100%. Qinglong Group optimizes costs through the following measures: using high-strength tooling board instead of steel molds, reducing costs by 40%; optimizing tool paths through programming to reduce idle travel; and selecting resin or silicone molds for small-batch projects to lower initial investment.

Design optimization is key. Setting openwork patterns reasonably and avoiding overly fragmented disconnected areas reduces mold complexity and damage rates. In the Dongguan project, irregular openwork was optimized into parametric array patterns, increasing mold life from 50 uses to 150 uses. Increasing production batches is an effective way to amortize costs; through modular design, a single mold can produce a variety of variant components.

The application of new processes reduces costs. 3D-printed sand or wax molds are being explored, suitable for single-piece or small-batch complex shapes. Qinglong Group has established a mold-sharing platform, allowing molds for common openwork patterns to be reused across projects. Through full life-cycle cost management, the overall economic benefits of openwork UHPC are significant.