This study presents a simulation-based framework to analyze resource consumption and cost effects of product family design strategies. Drawing on Extended Axiomatic Design (EAD) and 53 documented design cases, we simulate empirically grounded patterns that reveal denser, more homogeneous resource use than benchmarks from cost accounting literature. The findings (1) provide a reusable dataset; (2) demonstrate the value of EAD for standardized product family design and enhanced cost transparency; and (3) support broader generalization of cost accounting insights.

Product variety increases complexity across product, process, and organizational domains, yet existing complexity measures offer limited guidance for design decisions. This study implements established metrics within a framework to enable consistent assessment across domains. The results reveal substantial redundancies among these metrics - with the notable exception of modularity, emphasizing its central role in complexity management. The consolidated measure set provides practitioners with a systematic basis for evaluating design strategies and managing complexity in product families.