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Has anyone worked on a custom functionality for calculating lead times for current open sales order/future sales order based on own capacity?

That is one of the next things on my to do list. Not sure it will help but the rough plan was to a popup suitelet on each Sales Order page that triggers a few searches etc and then calculate the result into ATP dates

I guess that could work for current orders.
For new orders, which is still in discussion with customer, we would need a custom page where someone could enter in the product they are looking the lead time for.

But I’m still not sure what all things to consider when calculating lead time as there could be so many variables here.

Does sound alot like what the standard ATP offers, we just have to work around that due to a fairly volatile supply chain that can't run with static lead times

Yeah, as above, lead times are our downfall, currently working on cleaning up the transactions for inbound stock with some custom records so that I can use actual dates on a per order basis

What is you lead-time calculation ... purely stock levels and inbound replenishment?

For us, we want to consider our production capacity, on-hand stock and current demand from sales orders.