Low-volume and production
What is low-volume manufacturing, and when does it make sense?
Low-volume manufacturing means producing anything from one part to a few thousand without committing to production tooling. 3D printing, CNC machining and soft tooling all compete in this range. As a guide, print up to a few hundred parts, use SLS for batches of small parts up to a few thousand, and machine when tolerance or metal demands it.
Reviewed by HenleyPrint3D engineers3 min readUpdated
Key takeaways
- Print for 1 to a few hundred; SLS batches work up to a few thousand.
- Machine when tolerance or metal demands it.
- Bridge production covers the gap while tooling is made.
- Tooling pays back from a few hundred parts upwards.
Suits
Teams producing from one part to a few thousand.
Worth knowing
Quantities and break-even points here are typical. Part size, material and tolerance move them, so send the quantity with your file.
Low-volume production routes compared
| Route | Typical volume | Set-up | Limit |
|---|---|---|---|
| FDM | 1 to several hundred | None | Layer lines, slower per part |
| SLS | 10 to a few thousand | None | Small build, matte surface |
| CNC machining | 1 to a few hundred | Programming and fixtures | Cost rises with complexity |
| Urethane casting | 10 to a few hundred | Master and mould | Limited mould life |
| Injection moulding | From several hundred | Tooling, often thousands of pounds or more | Tooling cost and lead time |
Which route for which quantity?
| Your situation | Route |
|---|---|
| 1 to a few hundred plastic parts | FDM |
| 10 to a few thousand small parts | SLS |
| Tight tolerance or metal | CNC machining |
| 10 to a few hundred parts with a moulded finish | Urethane casting |
| Several hundred or more, design settled | Injection moulding |
Key figures
| Figure | Value |
|---|---|
| FDM or SLS set-up cost | None |
| Fastest FDM turnaround | 1 calendar day |
| SLS lead time from | 2 calendar days |
| Components produced to date | 312,467 across 21 countries |
Planning a low-volume run
Send the quantity, the target date and any tolerance-critical features with the first request. FDM and SLS carry no set-up cost, so a run of 20 costs about the same per part as a run of 100 until nesting and batch effects take over. SLS batches nest parts in three dimensions, which lowers cost per part as the run grows. If the design may still change, print first and cut a tool once it settles. If tooling will take weeks, run bridge production on printers in the meantime so product is not held up.
For the break-even calculation, see 3D printing vs injection moulding. To order a batch, see our low-volume manufacturing service and SLS 3D printing for nylon batches.
Frequently asked questions
What quantity counts as low-volume manufacturing?
Roughly 10 to a few thousand parts. Below that is prototyping, and above that tooling-based processes such as injection moulding usually give the lowest unit cost.
Is 3D printing cost-effective for production?
It can be for low volumes, because tooling cost is zero and parts nest in a build. The break-even against moulding typically lies between a few hundred and a few thousand parts, depending on part size and complexity.
What is bridge manufacturing?
Using 3D printing or soft tooling to supply parts while production tooling is being built, so a product can launch, or be tested, earlier and with lower risk.
How do you keep 3D-printed batches consistent?
Freeze the build parameters, record material lots, inspect first articles and samples, and keep traceability from part to build. Consistent finishing matters as much as the printing itself.
Which 3D printing process is best for batches?
SLS in nylon PA12 is usually the best choice for batches of small to medium parts because it needs no supports and parts nest in three dimensions. FDM suits larger or tougher parts at lower quantities.
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