When developing a new product, the leap from design to production is one of the biggest challenges to overcome. With traditional manufacturing methods, even the simplest parts can require weeks of time and thousands of dollars in tooling costs. These costs may be prohibitive for small scale production of 100-1000 parts.

A small production run of 3D printed parts using ABS plastic.

Fortunately, there are a number of options available which are more appropriate for smaller scale production, including:

Additive manufacturing / 3D printing: parts are created by fusing thin layers of plastic together.
Urethane casting: parts are created from a soft mold, which is created using liquid silicone which cures around a master object
Aluminum tool injection molding: Parts are created in the same way as traditional injection molding, but tooling is made with aluminum, which is easier to machine.

Per-part production costs for these methods are more expensive than traditional manufacturing methods, but the total cost and time investment for a small-scale production run are significantly lower. Each of these methods is best for different applications:

One part of a silicone mold used to form urethane parts.

3D printing is best when cost and timeline are the most important factors. It is not suitable for parts with specific material or strength requirements, or that require a smooth surface finish. However, if a part can be produced suitably using 3D printing, it is often the best option in terms of cost, timeframe, and ease of revision for low volume production runs.
Urethane casting uses a soft mold to produce parts, which is much easier to create than aluminum or steel tooling. However, these molds cannot be used with many materials and typically can only last long enough to produce 75-100 parts at most before the mold wears out.
Aluminum tool injection molding costs less than traditional steel tooling to create, but can be expensive and slow. When quality or material are critical in part production, it is the best option.

An aluminum mold and injection molding machine used to create a production run of a plastic part.

Use this table to help you compare the available options and decide which is best for your application. If you want to learn more, we’d love to discuss your project with you. Even if it isn’t a good fit for 3D printing, we’re happy to help you choose the right path forward.

	3D Printing	Urethane Casting	Aluminum Tool Injection Molding
Upfront Tooling Costs	None	Low cost $300 - $1000	High cost $500-$5000
Per-Part Costs	Moderate	Low, but mold can only be used for one production run	Very low. Molds can be used for multiple production runs.
Typical Quantity	1-100	50-200	1000 -10000
Production Timeline	2-5 days	1-2 weeks	3-5+ weeks
Part Strength	Moderate. Not suitable for high stress applications.	Moderate. Limited material options.	Best. Many material options.
Part Geometry and Detail	Moderate detail. Not suitable where a smooth surface finish is required.	Better detail. Versatile thickness and geometry.	Most detailed. Requires thin, uniform walls and drafts for mold removal.
Ease of Part Design Iteration	Very easy. New iterations can be seamlessly integrated mid-production.	Moderate. Molds are used for one run and need to be rebuilt for every run of 5-75 parts.	Difficult. In most cases new tooling must be created at the same upfront cost.

How to Choose A Manufacturing Method For Low Volume Production

©2021 3DPros LLC