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Hardware development cost calculator

The cash you need before your first sale: prototype, moulds, safety testing and your first factory order. Pick your product type and where it sells. Every line shows why it applies.

Short answer · Reviewed Oct 2026

A physical product typically needs about $35,500 to $160,500 in cash before its first sale, using the calculator's defaults: a Bluetooth product with a built-in lithium battery, four moulded plastic parts, and a first order of 1,000 units at $12 each, sold on Amazon in the US and Canada. That covers the prototype, injection moulds, safety and certification testing and the first factory order.

Prices checked October 15, 2026 · 22 published sources · see them all
1What it isBuilt-in lithium · Bluetooth / Wi-Fi · Adults
Power
A rechargeable battery built in. Adds battery safety and shipping tests.
Wireless
Using a pre-certified module. That skips the most expensive radio testing.
Made for children 12 or underAdds third-party lab testing for children’s products.
2Where it sellsUS + CA · Amazon
Markets
Pick every market you plan to sell in. At least one stays selected.
Main channel
Amazon and retail buyers usually ask for product liability insurance.
3How many you make4 parts · 1,000 units
Moulded plastic parts
4
First order
Count each plastic piece with its own shape. Screws and the circuit board don’t count.
Boxed size
Use your factory’s quote if you have one. Boxed size 20 × 15 × 7 cm, which sets the freight.
Cash you need before your first sale
$35,500–$160,500

For a Bluetooth or Wi-Fi product with a built-in lithium battery, 4 moulded parts, 1,000 units, sold on Amazon in US + Canada.

Prototype is your biggest cost, about 30% of the total. Most of this goes on revision rounds, so lock the design early.

  • Looks-like model$300–$2,000Needed for every product.Shows size, shape and finish. Studio price, design time included.Analogy Design ↗
  • Works-like model$2,000–$20,000Needed for every product.Proves the mechanism or circuit works. Studio price, design time included.Analogy Design ↗
  • Electronics and firmware for a connected product$5,000–$30,000Because it has a radio.Circuit board, sensors and firmware on top of the works-like model.Analogy Design ↗
  • Aluminium injection mould$6,000–$40,000One tool for each moulded plastic part. 4 parts × $1,500–$10,000.Aluminium tools last 10,000 to 100,000 shots, enough for a first order. Steel tools for high volume start near $10,000.Protolabs ↗Prototek ↗
  • FCC testing with a pre-certified radio module$6,500–$10,000Because it uses Bluetooth or Wi-Fi through a pre-certified module.Can cost more if the module’s grant does not cover use close to the body.47 CFR Part 15Compliance Testing LLC ↗Sunfire Testing ↗US
  • Battery cell and pack safety$0–$30,000Because it has a built-in lithium battery.$0 if your cell supplier already holds the certificates; $10,000 to $30,000 if they don’t.UL 1642 / UL 2054 / IEC 62133-2MarkReady ↗
  • Lithium battery shipping test$1,700–$2,100Carriers won’t ship a built-in lithium battery without it.Carriers won’t ship lithium batteries without it.UN 38.3JJR Laboratory ↗
  • Canada radio certification and Canadian representative$0–$3,600Because you sell a radio product in Canada.About $3,000 testing plus $600 for a Canadian representative (2019 quote). A pre-certified module can already carry ISED certification.ISED RSSSparkFun Electronics ↗CA
  • First order from the factory$12,000Your factory price, paid before every product ships. 1,000 units × $12.Your factory price per unit. Usually 30% deposit at order and 70% before it ships, so the whole order is paid before your first sale.Youna Global ↗
  • Ocean freight from China (shared container)$250–$600Needed for every product. 2.1 m³ × $120–$285 per m³.Priced on the China to US route: $120 to $200 per cubic metre to Los Angeles, up to $285 to New York; ocean only, 1 m³ minimum. Origin, customs and delivery are extra, and other routes differ.Fasary Logistics ↗Freightos ↗
  • Printed retail box$1,000–$8,000Needed for every product. 1,000 boxes × $1.00–$8.00.From a folding carton to a rigid gift box; rigid boxes cost 3 to 5 times more.Cubit Packaging ↗
  • UPC barcode (GS1 US)$30–$300Needed for every product.$30 for one barcode, or $250 plus $50 a year for 10.GS1 US ↗
  • Product liability insurance, first year$740–$1,900Because you sell on Amazon or retail stores.Amazon requires it for lithium electronics and children’s products from Nov 2, 2026; lithium products can cost more to insure.Forbes Advisor ↗ecom.insure ↗
  • Import dutyNo public priceApplies to every product you import.Depends on the tariff code; no single figure applies.Youna Global ↗
Cash before first sale$35,500–$160,500
Then 15 to 75 days of factory production, depending on the product, and about 30 to 40 days door to door by sea.
1 cost has no public price and isn’t in the total.

Indicative ranges from vendor-published prices, checked October 15, 2026. Not a quote and not legal advice: confirm what applies with an accredited lab. Prices in US dollars.

The four stages, cost by cost

Every figure the calculator uses, with when it applies and where it comes from. Labs and vendors publish most of these prices themselves, so treat them as indicative.

Prototype

Two models come first. A looks-like model shows the size, shape and finish. A works-like model proves the mechanism or circuit does its job. Connected products need electronics and firmware on top.

CostApplies whenPrice
Looks-like modelEvery product$300–$2,0001Shows size, shape and finish. Studio price, design time included.
Works-like modelEvery product$2,000–$20,0001Proves the mechanism or circuit works. Studio price, design time included.
Electronics and firmware for a connected productHas Bluetooth, Wi-Fi or a custom radio$5,000–$30,0001Circuit board, sensors and firmware on top of the works-like model.

Tooling

Each plastic part with its own shape needs its own injection mould. Aluminium moulds cost less and last long enough for a first order; steel is for high volume.

CostApplies whenPrice
Aluminium injection mouldEach moulded plastic part$1,500–$10,000 per part2,3Aluminium tools last 10,000 to 100,000 shots, enough for a first order. Steel tools for high volume start near $10,000.

Safety & certification

What you test depends on what the product has and where you sell it. Electronics, radios, lithium batteries, wall plugs and children’s products each bring their own tests, and each market has its own rules.

CostApplies whenPrice
FCC emissions test (Part 15B, self-declaration)47 CFR Part 15BHas electronics and no radio (US)$3,000–$5,0004
FCC testing with a pre-certified radio module47 CFR Part 15Bluetooth or Wi-Fi through a pre-certified module (US)$6,500–$10,0004,6Can cost more if the module’s grant does not cover use close to the body.
FCC radio certification (custom radio)47 CFR Part 15CA custom radio design (US)$9,000–$40,0004,5Lab and certification body fees run $9,000 to $12,000; consultancies quote $15,000 to $40,000 once engineering and retests are included.
Safety listing (UL, ETL or CSA)UL 62368-1 / 60335-1Plugs into the wall (US, Canada)$15,000–$30,0007Not required by federal law, but major retailers require it. ETL often costs 25 to 50% less than UL. Factory inspections then cost $12,000 to $20,000 a year.
Battery cell and pack safetyUL 1642 / UL 2054 / IEC 62133-2Has a built-in lithium battery$0–$30,0007$0 if your cell supplier already holds the certificates; $10,000 to $30,000 if they don’t.
Lithium battery shipping testUN 38.3Has a built-in lithium battery (every market)$1,700–$2,1008Carriers won’t ship lithium batteries without it.
Children’s product lab testing (CPSIA)CPSIA, 16 CFR 1107Made for children 12 or under (US)$400–$80013Lab fees per product, before the Children’s Product Certificate.
Canada digital-device emissions (ICES-003)ICES-003Has electronics and no radio (Canada)No public price11Self-declared. No public price; ask your lab to include it in the FCC test.
Canada radio certification and Canadian representativeISED RSSBluetooth, Wi-Fi or a custom radio (Canada)$0–$3,60010About $3,000 testing plus $600 for a Canadian representative (2019 quote). A pre-certified module can already carry ISED certification.
Canada children’s product safetySOR/2011-17Made for children 12 or under (Canada)No public price12Applies to toys. No public testing price found.
EU emissions test (CE, EMC)EMC DirectiveHas electronics and no radio (EU)$4009
EU radio test (CE, RED)Radio Equipment DirectiveBluetooth, Wi-Fi or a custom radio (EU)$680–$2,8009,10
EU electrical safety (CE, LVD)Low Voltage DirectivePlugs into the wall, or has a radio (EU)$450–$1,8009,10Radio products must meet the same safety requirements whatever their voltage.
EU toy safety testing (CE, EN 71)EN 71Made for children 12 or under (EU)$400–$8009
UK: CE marking acceptedSelling in the UK and the EU$015,14Great Britain accepts the CE mark for most electronics, so the EU testing covers it.
UKCA testing (no radio)UKCAHas electronics and no radio (UK, without the EU)$3,980–$10,61414£3,000 to £8,000, converted at £1 = US$1.3267.
UKCA testing (with radio)UKCAHas a radio (UK, without the EU)$6,634–$19,90114£5,000 to £15,000, converted at £1 = US$1.3267.

First production run

The first factory order is usually paid in full before it ships, so it all comes before your first sale, along with freight, boxes, barcodes and, for most marketplaces, insurance.

CostApplies whenPrice
First order from the factoryEvery productNo public price16Your factory price per unit. Usually 30% deposit at order and 70% before it ships, so the whole order is paid before your first sale.
Ocean freight from China (shared container)Every product$120–$285 per m³17,18Priced on the China to US route: $120 to $200 per cubic metre to Los Angeles, up to $285 to New York; ocean only, 1 m³ minimum. Origin, customs and delivery are extra, and other routes differ.
Printed retail boxEvery productNo public price19From a folding carton to a rigid gift box; rigid boxes cost 3 to 5 times more.
UPC barcode (GS1 US)Every product$30–$30020$30 for one barcode, or $250 plus $50 a year for 10.
Product liability insurance, first yearSelling on Amazon or in retail stores$736–$1,85421,22Amazon requires it for lithium electronics and children’s products from Nov 2, 2026; lithium products can cost more to insure.
Import dutyEvery productNo public price16Depends on the tariff code; no single figure applies.

What isn’t included

Patent costs, design fees beyond the prototype studio’s price, import duty (it depends on the tariff code), warehousing and marketing. Pound prices are converted at £1 = US$1.3267 (ECB reference rate, 14 Oct 2026). For patent costs, use the patent cost calculator.

Sources

Each page opened and read on October 15, 2026. The date is the one the page carries.

  1. How much does a prototype cost?Analogy Design · Jul 22, 2026
  2. Aluminum vs. steel toolingProtolabs · Dec 12, 2025
  3. A guide to aluminum vs steel tooling for injection moldingPrototek · Apr 20, 2026
  4. FCC certification costCompliance Testing LLC (accredited lab and FCC TCB) · Apr 24, 2025
  5. FCC and IC certification cost for BLE productsAmotus · Jun 4, 2026
  6. FCC certification costs guideSunfire Testing · 2024
  7. UL certification: the complete guide for electronicsMarkReady · Apr 22, 2026
  8. How much does UN38.3 testing cost?JJR Laboratory · May 6, 2024
  9. How much does CE certification testing cost?JJR Laboratory · Jun 8, 2024
  10. A founder’s FCC, ISED and CE certification costsSparkFun Electronics · Dec 3, 2019
  11. ICES-003: Information Technology Equipment (including Digital Apparatus)Innovation, Science and Economic Development Canada · Issue 7
  12. Toys Regulations (SOR/2011-17)Justice Laws, Government of Canada · current
  13. CPSIA compliance documentNational Bulk Vendors Association · Mar 2024
  14. UKCA marking costKrono Labs · 2026
  15. Radio Equipment Regulations 2017: Great BritainGOV.UK · current
  16. Sourcing consumer electronics from ChinaYouna Global · Jul 31, 2026
  17. LCL shipping from China to the USAFasary Logistics · Apr 22, 2026
  18. Shipping from China to the United StatesFreightos · 2026
  19. Custom rigid box pricing guideCubit Packaging · May 11, 2026
  20. How to get a UPC barcodeGS1 US · 2026
  21. Product liability insuranceForbes Advisor (AdvisorSmith data) · Mar 18, 2025
  22. Amazon seller insurance guideecom.insure · Sep 8, 2026

Hardware cost questions

You need about $35,500 to $160,500 before your first sale, using the calculator’s defaults: a Bluetooth product with a built-in lithium battery, 4 moulded plastic parts, and a first order of 1,000 units at $12 each, sold on Amazon in the US and Canada. That covers the prototype, injection moulds, safety and certification testing, and the first production run, including freight, boxes, a barcode and insurance. The range is wide mostly because of prototype studio fees and whether your battery cells already carry safety certificates.

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Before first sale$36k–$161k
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