AGVHub
How Much Does an AGV System Cost?
Realistic cost overview for AGV projects: Vehicle prices, infrastructure, software, and ongoing costs transparently explained.
Reading time: 3 min
The Short Answer
A single AGV typically costs between $50,000 and $250,000. A complete system with multiple vehicles, fleet control, and integration usually ranges from $300,000 to $2,000,000+.
These are reference values. Actual costs depend heavily on your specific requirements.
Cost Overview by Component
Vehicle Costs
| Vehicle Type | Price Range |
|---|---|
| Underride AGV (simple) | $30,000 – $80,000 |
| Underride AGV (lifting) | $60,000 – $120,000 |
| Tugger / Tow tractor | $50,000 – $100,000 |
| Forklift AGV | $100,000 – $200,000 |
| Heavy-load AGV | $150,000 – $300,000 |
| Special vehicles | $200,000 + |
Infrastructure
| Component | Cost |
|---|---|
| Reflectors (each) | $50 – $150 |
| Magnetic tape (per meter) | $10 – $30 |
| Charging stations | $5,000 – $30,000 |
| Floor work | Project-dependent |
| Network infrastructure | $5,000 – $50,000 |
Software & Integration
| Component | Cost |
|---|---|
| Fleet control (basic) | $20,000 – $50,000 |
| Fleet control (enterprise) | $50,000 – $200,000 |
| WMS integration | $10,000 – $100,000 |
| Interfaces (SAP, etc.) | $15,000 – $80,000 |
| Project management | 10-20% of total cost |
Example Calculation
Example: Mid-sized Manufacturing
3 vehicles, laser navigation, WMS connection
| 3x Underride AGV | $240,000 |
| Reflectors & installation | $15,000 |
| 2x Charging station | $20,000 |
| Fleet control | $45,000 |
| WMS integration | $35,000 |
| Project management & commissioning | $50,000 |
| Total | $405,000 |
Ongoing Costs
Beyond the investment, ongoing costs apply:
| Item | Annual Cost |
|---|---|
| Maintenance contract | 3-8% of vehicle cost |
| Spare parts | 1-3% of vehicle cost |
| Software maintenance | 10-20% of license cost |
| Energy | $500-1,500 per vehicle |
| Training | As needed |
Watch for Hidden Costs
Often underestimated costs:
- Floor remediation for poor conditions
- WiFi expansion for stable connection
- Modifications to transfer stations
- Training and change management
- Productivity loss during implementation
Financing Models
Besides outright purchase, alternatives exist:
| Model | Description | Suitable for |
|---|---|---|
| Purchase | One-time investment | Long-term use |
| Leasing | Monthly payments | Preserving liquidity |
| RaaS | Robot-as-a-Service, pay-per-use | Flexibility, pilots |
| Hire-purchase | Combination of rental and purchase | Transition model |
ROI Considerations
An ROI calculation should include:
Savings:
- Labor costs (wages, benefits)
- Reduced accidents and damage
- Higher availability (24/7)
- Lower error rates
Typical payback period: 2-4 years
Conclusion
AGV system costs vary widely. Get multiple quotes and compare not just vehicle prices, but Total Cost of Ownership (TCO) over the planned usage period.