Technology has improved to the point where it is possible to conduct cost analysis using CAD geometry. These Feature Based Cost Analysis programs should enable design engineers and product designers to have more insight and control over the component costs during the design phase. Here are some commercially available tools that I am aware of:
aPriori (www.apriori.com) Akoya (www.akoyainc.com). Software Gets a Grip on Costs article from 3 Nov 2005 issue of Machine Design. i-advisor from Imaginestics (www.imaginestics.com) Trim Manufacturing Costs During Product Design article from 1 May 2005 issue of Cadalyst magazine. eMachineShop (www.eMachineShop.com)
If anyone has additional information to add to this FAQ, please contact me.