·5 min read
From Prototype to Small-Batch Production with 3D Printing
You have a working prototype. Now you need 200. Here's how to scale 3D printing into real small-batch production without blowing the budget.
Below roughly 500 units, 3D printing beats injection molding on total cost, lead time, and flexibility. Between 500 and 5,000 it depends on part geometry. Above 5,000, mold.
Design tweaks that cut cost by 30%
- Orient the part so support material is minimal
- Hollow non-structural volumes
- Round sharp corners that catch on supports
- Design in press-fit or snap-fit joints instead of screws where possible
Quality control at volume
Ask your printer to sample every 25th unit and check critical dimensions. Reject any warped, delaminated, or under-extruded parts before shipment.
Talk to us before you finalize the design
A 15-minute call before you lock the geometry usually saves 20–40% on the per-unit cost.
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