I have a complex part that includes many repeated features, gear detail and corner radii. The number of surfaces imported from the CAD model is large. DFM Concurrent Costing is predicting a very high tooling cost. Are there adjustments I should make?

For parts with features that are repeated throughout, manually count surface patches rather than relying on the number of surface patches imported from CAD. Manually counting surface patches will allow you to adjust the surface patch count for the repeat features and will result in a much more accurate tooling cost estimate. When you're manually counting surface patches, you should apply the following correction to all features that are repeated on the part:

Surface patch count contribution of feature = Surface patch count on one feature * Repeat count of feature ^ 0.7

Round all surface patch contributions to the nearest integer value.