Low-volume and production
3D printing vs injection moulding: which is cheaper for your part?
3D printing is cheaper than injection moulding at low quantities because it needs no tooling. As a rule, print under about 100 parts. Moulding carries a tooling cost but a very low unit cost, so over about 5,000 identical parts it is cheaper. Between the two, the break-even depends on the tooling cost for your part.
Reviewed by HenleyPrint3D engineers3 min readUpdated
Key takeaways
- Under about 100 parts: print.
- Over about 5,000: mould.
- In between, calculate the break-even and consider bridge production.
- Print first when the design may still change.
Suits
Product teams deciding whether to print or tool a part for launch or volume.
Worth knowing
Break-even depends on tooling cost, so calculate it for your part. Under about 100 parts, printing is cheaper; over about 5,000, moulding is cheaper.
3D printing and injection moulding compared
| Factor | 3D printing | Injection moulding |
|---|---|---|
| Tooling | None | From a few thousand pounds (simple aluminium) to far more for multi-cavity steel |
| Unit cost at 10 parts | Low | Very high |
| Unit cost at 10,000 parts | Moderate to high | Very low |
| Lead time to first parts | From 1 to 2 calendar days | Tooling typically takes several weeks |
| Design change | A new file | Tool modification, slow and costly |
| Geometry | Draft set by build direction | Draft about 1 to 2°, uniform walls |
| Materials | Limited range | Hundreds of grades |
How to calculate the break-even quantity
Break-even quantity = tooling cost ÷ (printed unit cost − moulded unit cost). If the number is above what you expect to sell, print.
Choosing a route by quantity
| Your situation | Choose |
|---|---|
| Under 100 parts, or design still changing | 3D printing |
| 100 to 5,000 parts | Calculate; bridge with printing while tooling is made |
| Over 5,000 identical parts | Injection moulding |
Quantity thresholds and lead times
| Figure | Value |
|---|---|
| Print the part | Under about 100 parts |
| Mould the part | Over about 5,000 identical parts |
| Moulding draft angle | About 1 to 2° |
| Printing lead time | From 1 to 2 calendar days |
| Tool lead time | Typically several weeks |
A common pattern is to print the first run for launch, gather feedback from use, then cut the tool once the design is stable. Bridge production covers the weeks while the tool is made. Our low-volume manufacturing guide compares printing, machining and soft tooling for the quantities in between.
For production runs, see our low-volume manufacturing service. For what sets the price of a printed part, see how much 3D printing costs in the UK.
Frequently asked questions
At what quantity does injection moulding become cheaper than 3D printing?
Commonly somewhere between a few hundred and a few thousand parts. Divide tooling cost by the saving per part to estimate it; small simple parts break even earlier, and complex or large tools later.
How much does injection moulding tooling cost?
It ranges from a few thousand pounds for simple aluminium tools to tens or hundreds of thousands for complex, hardened steel, multi-cavity tools. Always take a quote for your specific part.
Is 3D printing as strong as injection moulding?
Moulded parts are isotropic and well characterised, while printed parts vary by process and orientation. SLS nylon is close to moulded nylon in many uses, while FDM is weaker across layers, so orient the load along them.
Can I print a prototype and then injection mould the same design?
Yes, but add draft, uniform walls and mouldable features first. A design optimised only for printing may need changes before it can be moulded.
What is bridge production?
Using 3D printing to make the first production parts while tooling is being built, so you can launch earlier and avoid tooling a design that may still change.
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