Earlier quoted context omitted.
I remember having manuals printed in the 1980s. The first manual cost $1000 to print, the second one $1. This was with camera-ready copy. Never mind all the cost of writing the manual, proofing it, and formatting it. When I worked at Boeing, the first forging of a part cost $250,000. The next, just a handful of dollars. At Boeing, the first airplane gets a ton of testing, as the design is being tested. Airplanes #2 a…
You still don't choose forging as a process to make quantity 2 (unless you absolutely need forged parts for strength). Instead, you're milling two parts from billet. Milling 2 parts from billet is cheaper per unit than milling 1 (some shared setup and programming costs), but it's the same amount of raw material and basically the same amount of operator time.
Even in custom machine work, the cost is in the setup. A machinist can make two identical cuts on two parts for not much more cost than one cut on one part.