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Fully self-hosted (Whisper + Pocket TTS + open LLM)
$0.0125
$0.0020
$0.0020
$0.0030
$0.0000
$0.020
1.5 Per-Call COGS (at various durations)
Using the current production stack at $0.097/min:
Call Duration
COGS
At $0.15/min price
Margin
At $0.25/min price
Margin
3 min
$0.29
$0.45
36%
$0.75
61%
5 min
$0.49
$0.75
35%
$1.25
61%
10 min
$0.97
$1.50
35%
$2.50
61%
15 min
$1.46
$2.25
35%
$3.75
61%
30 min
$2.91
$4.50
35%
$7.50
61%
60 min
$5.82
$9.00
35%
$15.00
61%
Using the cost-optimized stack at $0.073/min:
Call Duration
COGS
At $0.15/min price
Margin
At $0.25/min price
Margin
3 min
$0.22
$0.45
51%
$0.75
71%
5 min
$0.37
$0.75
51%
$1.25
71%
10 min
$0.73
$1.50
51%
$2.50
71%
15 min
$1.10
$2.25
51%
$3.75
71%
30 min
$2.19
$4.50
51%
$7.50
71%
60 min
$4.38
$9.00
51%
$15.00
71%
2. FIXED OVERHEAD COSTS (Validated)
2.1 Railway Hosting (Actual Bill)
Plan: Pro ($20/mo base, includes $20 usage credits)
Actual monthly cost: ~$28/mo
Resource
Usage
Monthly Cost
CPU (0.056 vCPU avg across 11 services)
2,417 vCPU-min
$1.12
Memory (2.5 GB avg across 11 services)
109,180 GB-min
$25.22
Disk (7 GB total)
304,177 GB-min
$1.06
Network egress (3.2 GB)
3.2 GB
$0.16
Total usage
$27.56
Pro plan base
included
11 services running:
Service
Type
Memory Driver
@phony/api
Node.js Fastify
Moderate
@phony/web
Nginx static
Low
@persona-labs/voice-api
Node.js Hono
Moderate
@persona-labs/pocket-tts
Python PyTorch
High (model weights)
@persona-labs/ingest
Node.js Fastify
Moderate
@persona-labs/ingest-worker
Node.js background
Low
developer-portal
Static
Low
@phony/db
PostgreSQL
High
@persona-labs/db
PostgreSQL
High
@persona-labs/vector-db
PostgreSQL + pgvector
High
@persona-labs/storage-console
MinIO
Moderate
2.2 Provider Subscription Fees (Monthly Fixed)
Provider
Plan
Monthly Cost
What You Get
Cartesia
Startup
$49/mo
1.25M chars TTS (~893 agent-minutes)
Cartesia
Scale (if needed)
$299/mo
8M chars TTS (~5,714 agent-minutes)
ElevenLabs
Pro
$99/mo (if subscribed)
500K credits TTS + STT
ElevenLabs
Free (current)
$0
Broken for cloned voices
Twilio
Pay-as-you-go
$0 base
Per-use billing
Twilio
Phone numbers (7 creators)
$8.05/mo
7 x $1.15
OpenAI
Pay-as-you-go
$0 base
Per-use billing
Stripe
Standard
2.9% + $0.30/txn
When active
Railway
Pro
$20/mo base
Included in hosting
Total fixed provider costs
$77-$327/mo
Depends on Cartesia plan
2.3 Total Monthly Overhead (No Revenue)
Category
Low (Cartesia Startup)
High (Cartesia Scale)
Railway hosting
$28
$28
Cartesia subscription
$49
$299
Twilio phone numbers
$8
$8
Domain/DNS
~$2
~$2
Claude Code / dev tooling
~$200
~$200
Total burn
~$287/mo
~$537/mo
2.4 Cartesia Included Minutes Before Overage
Your Cartesia plan includes a block of TTS credits. Here's how many agent-minutes you get before paying overage:
Plan
Credits Included
Agent-Minutes Included*
Effective TTS Cost if Fully Used
Pro ($5/mo)
100K chars
~71 min
$0.070/min
Startup ($49/mo)
1.25M chars
~893 min
$0.055/min
Scale ($299/mo)
8M chars
~5,714 min
$0.052/min
*At 1,400 chars/min average
Implication: On the Startup plan, your first 893 minutes of voice conversation per month have TTS "pre-paid." After that, overage kicks in at $0.039/1K chars.
3. SENSITIVITY ANALYSIS — What Moves the Needle
3.1 COGS Sensitivity (Current Stack: $0.097/min)
If this changes...
From
To
Impact on COGS/min
New Total
Switch LLM to GPT-4o-mini
GPT-5.2 ($0.025/min)
GPT-4o-mini ($0.001/min)
-$0.024
$0.073
Switch LLM to GPT-5-mini
GPT-5.2 ($0.025/min)
GPT-5-mini ($0.003/min)
-$0.022
$0.075
Switch STT to Deepgram
EL Scribe ($0.005/min)
Deepgram Nova-3 ($0.008/min)
+$0.003
$0.100
Self-host STT (Whisper)
EL Scribe ($0.005/min)
Self-hosted ($0.002/min)
-$0.003
$0.094
Double turn density (10/min)
5.5 turns/min
10 turns/min
+$0.050
$0.147
Halve turn density (3/min)
5.5 turns/min
3 turns/min
-$0.025
$0.072
Drop RAG context (no KB)
5 chunks injected
0 chunks
-$0.008 (fewer LLM input tokens)
$0.089
Cut TTS cap to 160 chars
320 chars/turn
160 chars/turn
-$0.027
$0.070
Use Pocket TTS (free tier)
Cartesia ($0.055/min)
Pocket TTS ($0.002/min)
-$0.053
$0.044
The two biggest levers:
TTS provider — Cartesia is 55-60% of your COGS. Pocket TTS eliminates it but has 13-30s latency.
LLM model — GPT-5.2 vs GPT-4o-mini is a 25% COGS swing. Need to test quality impact.
3.2 What Happens as You Scale
Monthly Minutes
Twilio
Cartesia (Startup)
STT
LLM (GPT-5.2)
Total Variable
+ Fixed Overhead
Cost/Min (All-In)
100
$1.25
pre-paid*
$0.50
$2.50
$4.25
$287
$2.91
500
$6.25
pre-paid*
$2.50
$12.50
$21.25
$287
$0.62
893
$11.16
pre-paid*
$4.47
$22.33
$37.96
$287
$0.36
1,000
$12.50
$4.17 overage
$5.00
$25.00
$46.67
$287
$0.33
5,000
$62.50
$160.26 overage
$25.00
$125.00
$372.76
$287
$0.13
10,000
$125.00
$335.53 overage**
$50.00
$250.00
$760.53
$537**
$0.13
50,000
$625.00
$1,582.00 overage
$250.00
$1,250.00
$3,707.00
$537
$0.085
*First 893 min included in Startup plan ($49/mo)
**Switch to Scale plan ($299/mo) at ~5,700+ min/mo
4. ALL-IN COST PER MINUTE (Overhead Amortized)
This is the number that matters for pricing — COGS + fixed costs spread across actual usage.
Monthly Volume
Variable COGS/Min
Fixed Overhead/Min
All-In Cost/Min
Min Price for 50% Margin
Min Price for 70% Margin
100 min
$0.097
$2.87
$2.97
$5.94
$9.90
500 min
$0.097
$0.57
$0.67
$1.34
$2.23
1,000 min
$0.097
$0.29
$0.39
$0.78
$1.30
2,500 min
$0.097
$0.11
$0.21
$0.42
$0.70
5,000 min
$0.097
$0.06
$0.16
$0.32
$0.53
10,000 min
$0.097
$0.05
$0.15
$0.30
$0.50
50,000 min
$0.085
$0.01
$0.10
$0.20
$0.33
Key insight: You need ~2,500+ min/mo before you can sustainably price at $0.25/min with healthy margins. Below that, fixed costs eat you alive.
5. PRICING RECOMMENDATIONS (Revised)
5.1 Voice API (Developer Platform)
Tier
Price
Included Min
Overage
Your All-In COGS
Margin on Overage
Free
$0
5 min
Hard cap
$0.49/min (at 5 min vol)
N/A (acquisition)
Starter
$29/mo
50 min
$0.12/min
~$0.10/min (at ~300 min total)
17%
Pro
$99/mo
200 min
$0.10/min
~$0.10/min
~0% on overage, margin is in subscription
Scale
$299/mo
1,000 min
$0.08/min
~$0.097/min
Negative on overage alone
Problem: At current COGS ($0.097/min), you can't profitably sell overage below ~$0.15/min. The subscription fee IS the margin.
Revised recommendation:
Tier
Price
Included Min
Overage
Where Margin Comes From
Free
$0
5 min
Hard cap
Acquisition cost
Starter
$49/mo
100 min
$0.15/min
Sub fee ($49 covers 100 min COGS of $9.70) = 80% margin
Pro
$149/mo
500 min
$0.12/min
Sub fee ($149 covers 500 min COGS of $48.50) = 67% margin
Scale
$499/mo
2,500 min
$0.10/min
Sub fee ($499 covers 2,500 min COGS of $242.50) = 51% margin
5.2 Phony Consumer Product
At current COGS of $0.097/min, the old $2.50/min was actually fine on margin (96%) but terrible for adoption.
Plan
Price
Minutes
COGS
Gross Profit
Margin
Free trial
$0
3 min one-time
$0.29
-$0.29
CAC
Casual
$4.99/mo
15 min
$1.46
$3.53
71%
Regular
$14.99/mo
60 min
$5.82
$9.17
61%
Power
$29.99/mo
150 min
$14.55
$15.44
51%
Pay-as-you-go
$0.25/min
Unlimited
$0.097/min
$0.153/min
61%
5.3 Creator Revenue Share (If Applicable)
If creators get a cut, it comes out of platform gross profit:
Consumer Plan
Revenue
Creator Share (50%)
Platform After Creator
COGS
Platform Net
Net Margin
Casual ($4.99)
$4.99
$2.50
$2.50
$1.46
$1.04
21%
Regular ($14.99)
$14.99
$7.50
$7.50
$5.82
$1.68
11%
Power ($29.99)
$29.99
$15.00
$15.00
$14.55
$0.45
2%
At 50% creator share, margins are razor-thin. You'd need either:
Lower creator share (30-40%), or
Higher prices, or
Much lower COGS (switch to GPT-4o-mini = instant ~25% COGS reduction)
With GPT-4o-mini (COGS drops to $0.073/min):
Consumer Plan
Revenue
Creator Share (50%)
Platform After Creator
COGS
Platform Net
Net Margin
Casual ($4.99)
$4.99
$2.50
$2.50
$1.10
$1.40
28%
Regular ($14.99)
$14.99
$7.50
$7.50
$4.38
$3.12
21%
Power ($29.99)
$29.99
$15.00
$15.00
$10.95
$4.05
14%
6. DEVELOPMENT & TEAM COSTS
6.1 Current Burn Rate
Item
Monthly Cost
Railway hosting
$28
Cartesia Startup plan
$49
Twilio phone numbers
$8
OpenAI API (dev/test)
~$20
Claude Code / AI dev tools
~$200
Domain, DNS, misc
~$5
Total burn (no salaries)
~$310/mo
6.2 Replacement Cost of What's Been Built
Component
Person-Months
At $15K/mo contractor
At $25K/mo senior
Voice pipeline (Twilio + TTS + STT + LLM)
4
$60K
$100K
Agent runtime (15 tools, providers, conversation)
3
$45K
$75K
RAG pipeline (ingest, hybrid search, pgvector)
2
$30K
$50K
Phony API (auth, billing, creators, calls)
3
$45K
$75K
Phony Web (consumer + builder portal)
2
$30K
$50K
Voice API (developer platform, BYOK, tiers)
2
$30K
$50K
Developer portal
1
$15K
$25K
DevOps (Railway, Docker, CI/CD)
1
$15K
$25K
Voice cloning (7 creators, 3 providers)
1
$15K
$25K
Quality/eval (self-play, scorecards)
1.5
$22.5K
$37.5K
SDK packages (5 packages)
1.5
$22.5K
$37.5K
Total
22 mo
$330K
$550K
6.3 Team Scaling
Stage
Trigger
Team
Monthly Payroll
Total Monthly Burn
Now
Pre-revenue
1 founder + AI tooling
$0
~$310
Seed
$500K raise
2 founders + 1 eng
$25K
~$25.5K
Post-seed
$10K MRR
2 founders + 2 eng + 1 design
$45K
~$46K
Series A
$2M raise
2 founders + 4 eng + 1 design + 1 GTM
$100K
~$102K
Growth
$100K MRR
2 founders + 8 eng + 2 design + 3 GTM
$200K
~$202K
6.4 Break-Even Points
Monthly Expense
Users Needed (at $14.99 Regular plan, 61% margin)
Minutes Needed (at $0.25/min PAYG)
Cover infra ($310/mo)
34 subscribers
2,026 min
Cover infra + 1 hire ($10K/mo)
1,094 subscribers
67,320 min
Cover infra + seed team ($25K/mo)
2,733 subscribers
165,360 min
$100K MRR
6,671 subscribers
400,000 min
7. RISKS AND UNKNOWNS
Risk
Impact
Mitigation
Cartesia price increase
TTS is 55% of COGS; 2x price = COGS goes from $0.097 to $0.152
Multi-provider support already built; can switch to Deepgram Aura ($0.030/1K)
GPT-5.2 pricing not confirmed
Using GPT-5 published rates; actual GPT-5.2 may differ
Test GPT-4o-mini quality; if acceptable, switch and save 25%
Turn density higher than estimated
Dense Q&A = 8-10 turns/min; COGS could be $0.13-0.15/min
TTS char cap already enforces output limit; main risk is LLM input tokens
ElevenLabs STT actual rate
$0.22-0.40/hr range is wide; depends on plan tier
Switch to Deepgram Nova-3 ($0.0077/min) for predictable pricing
Why: You have the best stack in the market. Competitors on Llama 70B + Groq charge $0.07-0.12 for a B-tier product. You can charge $0.25-0.35 for an A+ tier product. Don't race to the bottom.
Quick win: Switch STT from ElevenLabs Scribe ($0.005/min) to Groq Whisper Turbo ($0.001/min) — saves $0.004/min, same quality for call transcription. COGS drops to $0.100/min.