Here is my $0.02
I have extensive MFG Operations and Strategic sourcing experience, so take what I say for what its worth (to you
)
Patterns are not cheap, and the price of the pattern and castings must be absorbed.
So you can amortize it over 20,00 or 1000 units. So you see, the cost is substantially different between the two!
A pattern for such an integral casting would not be cheap, and would be in the $100-$150K, easy.
Even if you have the patterns, one would need a GREAT casting manufacturer, and they MUST understand castings. (trust me, not all of them do)
There are specific casting procedures that must be followed. Any shortcut, you can kiss the quality goodbye!
The EPA is cracking down daily on businesses that emit particles and gasses into the air, land, and water. It is not cheap to do business in the USA, especially CA.
That brings us to LCC sourcing (Low Cost Country Sourcing)
Let’s say you end up in China; Now lets review cost, quality and pride.
Cost;
China has proven to be the least expensive overall. Heck they are about 60% cheaper than Brazil, and 40% less than India! Mexico is no longer competitive.
Quality;
China has some GREAT knowledge, but, you MUST stay on them, and make 100% sure they understand your expectations of quality. If you get to that point, it will be more expensive that the average “casting house”, but, you should be able to get the parts a lower cost than most places around the world.
Pride; Well, there is only one way for this – “Made in America”.
So, in the end, it comes down to what Mike had stated;
Market qty, market expectations, sales volume and capital investment.