FDM vs SLA Cost Calculator

Frequently Asked Questions

How does the comparison work?

For the same part, the tool estimates FDM (filament weight × $/kg + FDM electricity) vs SLA (resin mL × $/L + UV LED electricity + IPA wash). Time is computed per technology so total cost can be compared side-by-side.

Which is cheaper per part?

For mid-to-large mechanical parts FDM almost always wins on material: PLA ≈ $0.02–0.03 per cm³, standard resin ≈ $0.05–0.10 per cm³. SLA wins on small, highly detailed parts because tiny FDM prints take disproportionately long.

What about hidden costs?

SLA adds wash IPA or water (≈$0.50–2.00/print), FEP film replacement (≈$30 per ≈150 print hours), and post-cure energy. FDM adds nozzle wear, belt/bearing maintenance, and a higher failure rate on long prints.

When is the time difference significant?

SLA prints in parallel across the build plate (time depends on Z height only), so 10 identical small parts can print in nearly the same time as one. FDM time scales roughly linearly with quantity, making SLA much faster for small-part batches.

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This calculator provides estimates for informational purposes only. Results are based on assumptions and may not reflect actual outcomes. Consult qualified professionals in relevant fields before making important decisions based on these results.

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How This Calculator Works

FDM and SLA produce the same part with completely different economics. FDM filament is cheap per gram ($20–30/kg for PLA), prints relatively fast on volume, and uses 60–150 W with low wear cost. SLA resin is 2–3× more expensive per equivalent volume ($40–60/L), the printer runs cooler at 40–80 W, but FEP sheets and LCDs are real consumables that drive wear cost to $0.15–0.30/h vs FDM's $0.05–0.10. This calculator lets you put both technologies side by side for the same part: enter the filament weight + hours on the FDM side and the resin volume + hours on the SLA side and see which is cheaper, by how much, and which is faster.

Formula / Method

FDM cost = (grams ÷ 1000) × $/kg + (W ÷ 1000) × hours × $/kWh + wear $/h × hours. SLA cost = (mL ÷ 1000) × $/L + (W ÷ 1000) × hours × $/kWh + wear $/h × hours. Slicers report filament weight and resin volume directly; for an apples-to-apples comparison, use the same dimensional part on both. Note that resin parts are denser than typical infill FDM - a hollow FDM 32 cm³ part at 20% infill weighs ~14 g (PLA), while the equivalent solid resin print is ~35 mL with 7 mL of supports ≈ 42 mL pumped.

Worked Example

A 32 cm³ bracket. FDM (PLA, 120 g with shells and 20% infill on a large flat profile): material = $2.64, electricity for 6h at 120 W = $0.115, wear $0.48 → total $3.24, 6 hours. SLA (resin, 140 mL including supports): material = (140÷1000)×45 = $6.30, electricity for 5h at 60 W = $0.048, wear $1.00 → total $7.35, 5 hours. FDM wins on cost ($4.11 cheaper); SLA wins on time and surface finish. For a 5 cm³ tabletop miniature with fine detail: SLA at $0.80 material plus pennies of overhead beats FDM's 30–60 min print time and visibly stair-stepped finish - cost wins for FDM but quality wins for SLA. The cost difference matters more for prototypes (FDM), the quality difference matters more for sellable final parts (SLA).

Common Mistakes

Comparing FDM and SLA without normalizing on the same part dimensions - resin is solid by default; FDM is mostly empty space at typical infill.

Ignoring post-processing - SLA needs IPA wash + UV cure (15–30 minutes labor + IPA cost); FDM needs only support removal.

Forgetting SLA consumables - FEP sheets ($5–15) need replacement every 30–60 prints; LCDs ($30–100) last 1500–3000 hours.

Not pricing your labor - SLA needs cleaning of the vat between resin types; FDM is "set and forget" for most jobs.

Assuming SLA is always slower - it is independent of part count, so a build plate of 20 miniatures has the same time as 1 miniature.

Tips & FAQ

When does FDM beat SLA? Larger parts, functional prototypes, anything where the surface finish does not matter or sanding/painting is planned, parts that need impact resistance (FDM PETG/PLA outlasts brittle standard resin). When does SLA beat FDM? Detail-heavy minis, jewellery, dental and medical models, tabletop figures, small-part batches (cost scales sub-linearly because plate fills evenly). What about tough resin? Tough or ABS-like resins close the durability gap with FDM but cost $60–100/L. Which is safer? FDM - resin is a sensitiser; some people develop allergic skin reactions; always wear nitrile gloves and ventilate. Hybrid? Many makers run both: SLA for the visible detail parts, FDM for the bulky structural ones. Total cost of ownership? A $200 FDM + $30/kg PLA versus a $250 SLA + $50/L resin + $40 wash-cure + $15 FEP per batch - over a year of regular use, FDM is typically 30–50% cheaper per print. Speed comparison: SLA wins above ~5 parts per plate; FDM wins single-part comparisons. These are planning estimates - track actual costs for your shop to refine the model.

FDM vs SLA Cost Calculator

Frequently Asked Questions

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