I wish it was only just the lathe costs and milling costs. Generally speaking there's a "set-up" fee to start any job. I've been quoted as low as about $300 and as high as about $1000 depending on the shop and the job.
The machining is also hugely dependant on the materials being used. I've seen some harder/exotics be more than quadruple what you're suggesting more especially if there's tight tolerances.
It still doesnt change the fact that you have to buy materials first. Oh, you want 1,000 of these, yeah that's going to be $1,000+ in material first. Not sure where you are, but last I checked, $1,000 isnt just lying around in my bank account. Oh, you're upset that I cant make more than 1,000 items at a time to keep in stock? Yeah, I'd love to do that, but I cant get the $15,000-$20,000 together for materials alone, then get the $300-$1000 setup fee, then something in the neighborhood of $5-$20 per unit to get that finished. Keeping in mind that most mods arent just a single piece being machined.
Yeah, I've looked into it a few times for a few different products. Yeah, once you're making 10,000 or more, that stuff gets cheaper per unit, but you still have to have money up front to finish the job before you can sell anything. It get's even cheaper if you can do a run of 1,000,000. But 1,000,000 pennies is still $100,000.
First, I get what you are saying. Most Mod makers are like me, they have a unique skill set that allows for free development costs. Then add in access to cheap or free machine time in the garage or at workplace. At both of my last shops I could have come in and utilized everything for free during down-time periods if I wanted, including our stock tooling, just buy my own material. As long as it was a personal project, and not undercutting their business they did not care. The owners probably would have been fine with me making mods, and selling them to start-up my own business. Eventually after a few runs I would need to start paying shop rate, of course. I just was there so damn much, I never wanted to spend any free-time at the shops. Also, that was several years ago and stupid in hindsight for me not to utilize the ability. 6-7 days a week and 60-80+ hours will do that to you though.
Have you checked out the manufacturing quoting websites? A lot of the shops quoting are hungry for work, some may possibly run a sample run of 20-100 parts if hungry enough. The important thing is to get contacts with companies that have experience with your choice of material (my suggestion is Brass/Copper as that is popular and cheaper to machine then most exotics). Spend some time getting passionate about machining and make contacts, then quotes should be realistic (see below). I understand there are other costs involved to making a quality piece and start-up costs. Tooling does cost money. Most shops build in expected reject/rework rates into their prices, and deburring or cosmetic finishes will cost extra or is easy to do on brass/copper yourself. However, those costs add up to a small percentage of the overall mod cost. Using your example of $2,000 in start-up costs ($1,000 for material and $1,000 for tooling) with a 12pc per hour (large underestimate for most brass mods on Swiss turn) at $120/hr for brass or copper (easy to machine) your total for 300 pieces is $5,000 which is basically $20 per custom tube and this is honestly high for most mods. Tack on another $30 for miscellaneous parts and packaging per mod and you are at $50 for actual out of pocket costs. Sell the mods for $200 on a limited first run release. Release them weekly in small batches to cover your $30 per mod extra expenses, and start-up costs can be kept to under $6,000 plus legal expenses to setup a limited liability company. Screw insurance, take the company bankrupt if sued by an idiot. Why do you think there are exclusive lists, this is to cover the mod makers personal liability at a minimum cost. This will yield $60,000 subtract costs of $15,000 plus legal expenses and there is $40,000+ a healthy approximate 300% profit. There is your working capital to make a 1,000 piece order.
Obviously, this business model is for those that have engineering/designing or extensive machining experience. Material selection, understanding tolerances, and real blue-prints are a minimum requirement to get a "serious" quote in this business. Otherwise, yes you are correct it will probably be much closer to $20,000-$30,000 to start-up, as you would be depending on your hand being held which is not cheap or without substantial risk financially to shops. Machine shops can smell newbies in the air and will eat them alive. Newbies waste a lot of time with dreams, and unrealistic expectations. Shops know when they are quoting a Newbie, and that this will probably be the only job they see from them. They need to make good money from day one on these types of jobs.
Edited:
I have shared more than enough knowledge on this topic, and do not want to ruffle any more feathers from my past profession. Do mod makers make money? Yes! Is it as easy as buying a tube threader and selling a copper pipe for $200? Heck No! I hope you have read my posts and are realizing that I have been telling a tale of a person that could be a high-end mod maker, if they choose. Guess what? It is more hassle/risk than it is worth to me, and I could be a one man team from product development to finished good. Honestly, if you are not in the manufacturing industry at the level I have been talking about, you probably should just buy a clone, or realize that the original mod maker is making good, but not obscene money. Put down whatever you are "vaping", and step away from the dreams of buying a tube threader and some copper tubing, and becoming a millionaire over night. The ceiling is set high to enter the American manufacturing business without prior knowledge.
If the mod maker has the skill set I have, and a few others that I know. They probably have been in the business for several decades, or worked 6-7 days a week 60-80 hours for at least a decade. Just so you could buy a major product from the slave driving company they worked for. They have worked harder than most people can comprehend, and are doing this as a passion or hobby. I am disappointed that many do not seem to have the business acumen to put together a brand worthwhile, and charge a reasonable price for authentic American made mods. That is all, I apologize if I have upset any mod makers. However, come on guys, this is a $2 billion industry ripe for the taking. Please, get your act together and reinvest your profits faster than you have been. Big tobacco and China are going to take decent jobs, and money from of our fellow Americans.
As I said from the get go, I will probably only buy authentic mods (atomizers are a different story).