SAW vs MIG/MAG Cost Crossover Calculator

Estimate the break-even cumulative weld meters where multi-torch SAW per-meter cost overtakes MIG/MAG, plus payback period for ABOKE membrane panel welding capex.

SAW machine capex (USD)total inc. installation

MIG/MAG existing setup capex (USD)to amortise vs SAW

Operator labor rate (USD/hour fully-loaded)

Continuous weld hours per week (single shift)

SAW per-meter consumable (USD)flux+wire net of recovery

MIG per-meter consumable (USD)wire+gas+spatter cleanup

SAW operators per line

MIG operators per line

SAW welding speed (m/min average)

MIG welding speed (m/min average)

Cost Crossover Analysis

SAW per-meter cost (consumable + labor + capex amort.) —

MIG per-meter cost (consumable + labor + capex amort.) —

Per-meter cost gap (SAW saving) —

Single-shift output (m/quarter) —

Δ Capex (SAW − MIG) —

Crossover meters (Δ Capex / Δ per-meter) —

Payback period (months at single-shift production) —

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Default values reference industry-average SAW capex for 4-torch standard model (~USD 250-320K), Lincoln Powerwave® AC/DC power source class. Labor rate uses fully-loaded EU/US median for welding-shop operator (~USD 25-40/hr). Per-meter consumable defaults derive from Megmeet + iKing + Red-D-Arc field analysis. Adjust to match your shop floor reality.

Powered by ABOKE field-cost data 2018-2025 + industry benchmarks (The Fabricator, Megmeet, iKing, Red-D-Arc). ← Back to main pillar page