Ballast Rugged Handheld Scanner · Manufacturing & Cost Engineering

COGS Working Model — move the levers that matter

A live per-unit cost-of-goods model for the Ballast platform. The handful of levers below are the ones worth moving: volume, the optics mix, the durometer call, battery capacity, display resolution, and where it’s built. Everything recomputes in front of you, and the delivered defaults reproduce the numbers in the cost model exactly.

Volume basis
25,000 / yr
Currency
USD
Posture
China + Mexico CM
NRE amortized over
3 yr / 75,000 u
Date basis
2026-08-23

The leversworth moving

Annual volume
The amortization denominator — spreads the ~$1M of NRE.
25,000
5k50k100k
Program life (NRE amortization)
Tools outlive year one. Amortize over the real program.
3 yr
1 yr3 yr5 yr
Long-range optics mix
Share of the fleet built with the SE55-class advanced-range engine. A line-side module swap, shared enclosure.
0%
all base 2D50/50all long-range
Grip durometer ⚑ HF
Single 90A, or dual 90A/75A two-shot for grip comfort. Felt in tooling NRE, not piece price.
Single 90A
Battery capacity ⚑ HF
Bay tooled for 20 Wh — Wh moves the cell cost, never the tool.
20 Wh
16 Wh1922 Wh
Display resolution
720p is the delivered default; 1080p is a real panel adder.
720p
Scan-engine tier (base 2D)
Merchant-OEM vs brand-class (Zebra/Honeywell/Datalogic). The client’s open engine question moves this line only.
Brand-class
Build & land
Ex-works factory gate, or landed to a US dock.
Ex-works

Per-unit COGS · base 2D · ex-works

$299/ unit

Blended fleet at 0% long-range · 25,000/yr

BOM (materials)$241.50
Conversion (assy + test + pack)$18.00
CM margin + yield (~10%)$25.95
NRE amortization$13.77
Per-unit COGS, ex-works$299
MSRP credibility check (on ex-works COGS)
at 3.5×$1,047
at 4.0×$1,196
at 4.5×$1,346
Category band, verified: Zebra TC53 $1,168–$1,453 · Datalogic Skorpio X5 $1,168–$1,410 · Honeywell CT47 mid-$1,000s. A credible COGS lands inside that band at 3.5–4.5×.

Where the cost livesBOM blocks

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Your inputs stay in your browser. This model runs entirely on this page, in JavaScript, on your own machine. Nothing you type or move is sent anywhere: no server, no studio, no network call. Close the tab and it’s gone. Reload to return to the delivered defaults.

Basis, locked on the model’s face: 25,000 units/yr · USD · contract-manufactured China-plus-Mexico · NRE amortized over a 3-year / 75,000-unit program life · date basis 2026-08-23. This instrument is a lens on the full cost model, not every BOM line: it exposes the handful of levers worth moving. The full line-by-line BOM, make-vs-buy, tooling detail, fragility analysis, and prototype-to-production roadmap live in cost-model.md, and the delivered defaults here reproduce that document’s numbers exactly.

Two levers carry a ⚑ HF flag: battery capacity and grip durometer are set from the human-factors pass, now resolved (2026-08-23). The durometer resolved to single 90A (the delivered default here), which saves the second overmold shot; the dual-90A/75A setting stays in the model as the documented escape-hatch cost so you can see what that decision saved. Battery is confirmed at the 20 Wh bay. Both levers remain movable so you can price any alternative yourself. Where a real contract price could not be pinned from public data, the underlying figure is a defensible range with its basis stated in the cost model; the single carry values shown here sit inside those bands.