Alternatives to Plastic Injection Molding for Small-Batches

Plastic injection molding is the primary method for manufacturing various plastic components, particularly suited for large-scale orders. However, its mold cost is high, and the production cycle is long. For small-batch production (tens to hundreds of pieces) and prototype development, there are more economical and rapid alternatives.

1. Vacuum casting

It is a good alternative to injection moulding for quantities between 10 and 50. Low cost, short cycle, and the option to use a variety of polyurethane materials (from soft elastomers to hard plastics like ABS), with good surface finish and an effect close to injection molded parts. It is often used for small-batch production of final products.

 Limitations: Silicone molds have a short lifespan (about 25 times), and their unit price is higher than that of injection molding.

2. 3D printing

3D printing has no molds required, it is the lowest cost, fastest speed, and capable of manufacturing complex geometric shapes, with an excellent surface finish using industrial-grade SLA technology. It is widely used in early prototypes, extremely small batch sizes (especially for small-sized parts).

 Limitations: Material selection and size are restricted, and the strength or quality may be inferior to injection molded parts.

3. CNC machining

CNC Machining is the highest precision and fastest turnaround option in small batches, which is suitable for robust and durable components with medium and small batch sizes and high-precision requirements.

Limitations: Not suitable for soft materials (rubber, silicone), and complex geometric shapes are costly and time-consuming.

Summary

The choice of which process to use depends on the order quantity, part complexity, material requirements, precision demands, and budget. Vacuum casting fills the gap from prototypes to medium-batch production. 3D printing is the preferred choice for extremely small-batch prototypes, while CNC machining ensures high-precision requirements. These solutions offer flexible and economical approaches for testing the market, user feedback, financing demonstrations, and small-scale production.

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