The Basic Economics
Cast bullets typically sell for $15–$30 per 100 depending on caliber and weight. A 9mm 125gr cast bullet might sell for $18/100. A .45 ACP 230gr might go for $26/100. Lead is your primary cost. Cast bullets are roughly 95–98% lead by weight, so your lead cost per bullet tracks closely with your source price and efficiency.
Cost Per Bullet — 9mm 125gr Example
| Cost Item | Per 100 Bullets |
|---|---|
| Lead (certified pure, ~$1.50–1.80/lb) | $1.30–$1.60 |
| Lubricant | $0.20–$0.35 |
| Electricity | $0.10–$0.20 |
| Packaging | $0.15–$0.25 |
| Labor (at $20/hr, 5,000 bph machine) | $0.40 |
| Total Cost | ~$2.15–$2.80 |
| Sale Price | ~$17–$20 |
| Gross Margin | ~75–85% |
Key insight: These margins assume automated equipment. With manual casting at 200–400 bullets/hour, labor cost per bullet jumps dramatically and can cut margins in half.
Production Rate vs. Hourly Revenue
| Production Rate | Revenue/Hour | Gross Profit/Hour |
|---|---|---|
| 500 bullets/hr (manual) | $90–$100 | $65–$75 |
| 1,500 bullets/hr (semi-auto) | $270–$300 | $195–$225 |
| 3,000 bullets/hr (M2R partial) | $540–$600 | $390–$450 |
| 5,000 bullets/hr (M2R full) | $900–$1,000 | $650–$750 |
Annual Income Potential
| Scenario | Production Days/Wk | Est. Annual Gross Profit |
|---|---|---|
| Side business | 1 day/week | $75,000–$130,000 |
| Serious side business | 2–3 days/week | $150,000–$350,000 |
| Full-time operation | 5 days/week | $400,000–$700,000 |
These are gross profit figures — before rent, insurance, payroll, and overhead. A home-based shop with low overhead can retain a significant portion as net income.
The M2R Automatic Casting Machine
Up to 5,000 bullets/hr. Built in the USA. Talk to Nick about specs and pricing.
Where Most Operations Leave Money on the Table
- Underpricing: Compete on consistency and availability, not just price
- Insufficient production rate: Manual equipment kills margins; serious income requires serious equipment
- Inconsistent lead sourcing: Alloy variation causes quality problems that cost customers
- No recurring customers: A shooting club or range buying regularly beats one-time gun show sales every time