I make vinyl decals for cars that are around 5" x 5" in size. I use several things when calculating cost. If it's custom for someone, I may charge a setup fee. That covers the time it takes me to design it, mock it up and maybe test cut it. That fee usually depends on the degree of difficulty. Then I have a base cost which is the average cost to make one decal (of the above mentioned size). This includes the cost of vinyl, transfer paper, packaging, instruction sheets (I have mine professionally printed on cardstock), and a fraction of the cost for blades and mats. Then I decide on a cost per hour and divide that by how many I can make in an hour and add it to my base cost. I also sell decals that are more than one color. For those I add a slight upcharge b/c it's more to weed, more vinyl being used, and more time for me to cut and join the colors. I have about 50 other tips and tricks if you're cutting bulk orders.

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I recently purchased a program from The Rhinestone World that is an excel spreadsheet that helps calculate the price per decal. I believe it was $10. I used that as a template and tweaked it to my own business. I'm happy to answer other questions if you have them!