How to Leverage Low-Volume Injection Molding: A Game-Changing Solution

The Problem: High Costs and Long Wait Times

Do you need custom plastic parts but feel stuck between high costs and long wait times? Traditional injection molding works great for making lots of parts, but when you only need a few hundred or a few thousand, it can be too expensive and slow. Many businesses face this exact problem – they want the quality of injection molding but can’t justify the big upfront costs.

The high tooling costs can reach $50,000-$100,000 for steel molds. The long lead times often stretch to 12-16 weeks. And the large minimum orders force you to make more parts than you actually need.

The Pain Gets Worse

This problem gets even more painful when:

• Your new product needs testing but you can’t afford final production tooling
• You have an urgent customer order but can’t wait months for tools
• You need parts with complex features that 3D printing can’t deliver
• Your budget is limited but you need production-quality parts
• You’re making medical devices that need FDA testing with real materials

Without a solution, you might end up:

• Delaying product launches
• Losing customers to faster competitors
• Wasting money on parts you don’t need
• Compromising on quality with less suitable manufacturing methods

As one customer told us: “We needed 500 parts for a medical trial, but traditional molders wanted us to order 10,000 minimum with a $75,000 tool. It would have killed our project before it started.”

The Solution: Low-Volume Injection Molding

This is where low-volume injection molding becomes a game-changer. It’s the perfect bridge between prototyping and mass production, giving you the best of both worlds.

Low-volume injection molding is a special approach to making plastic parts in smaller quantities (typically 50-10,000 parts) with faster turnaround times and much lower tooling costs.

At , we’ve helped hundreds of customers solve this exact problem using our specialized low-volume molding services.

Key Benefits:

• 60-80% lower tooling costs using aluminum molds instead of steel
• 2-week lead times versus 6+ weeks for traditional tooling
• No minimum order requirements – get exactly what you need
• Real production materials – same as mass production
• Full design flexibility – complex features, textures, and multi-material options

How to Make Low-Volume Injection Molding Work for You

1. Design Best Practices for Success

The way you design your part makes a huge difference in how well low-volume molding works. Here are the most important tips:

Simplify Your Geometry

• Keep walls uniform – between 0.040–0.150 inches thick
• Add draft angles – 1–2° per side for easy part ejection
• Use rounded corners instead of sharp edges
• Avoid undercuts when possible to simplify tooling

Our design for CNC machining guide shares more tips that apply to mold creation too.

Optimize Your Tooling Approach

• Choose aluminum molds for runs under 10,000 parts
• Consider family molds to make different parts in one shot
• Use inserts for complex features or areas that might change ![aluminum mold vs steel mold comparison]

Select the Right Materials

When planning your project, material choice makes a big difference:

Our CNC plastic expertise helps us recommend the best material for your specific needs.

2. Cost-Saving Strategies That Work

Smart planning can save you even more money:

• Use modular molds – swap inserts instead of making all new tools
• Optimize gate placement – reduce material waste by 15-20%
• Choose cold-runner systems for small batches to minimize waste
• Design multi-cavity tools when making identical parts

One automotive customer saved $8,000 by using our aluminum molds instead of steel for a run of 1,000 sensor housings.

3. Real-World Applications

Low-volume injection molding works great in many industries:

Medical Devices

• Silicone seals for FDA testing (500 units)
• Device housings for clinical trials
• Custom surgical tools in small batches

A medical device company got their validation parts 40% faster using our low-volume molding versus 3D printing.

Automotive Projects

• Overmolded sensor housings (1,000 units)
• Interior trim pieces for limited production runs
• Prototype light assemblies with clear lenses

Consumer Electronics

• Prototype casings with textured finishes (300 units)
• Custom connector housings
• Low-volume accessories for niche products

A consumer electronics startup got parts with a 2-week lead time versus 6 weeks for traditional tooling, helping them meet a critical demo deadline.

Choosing the Right Manufacturing Partner

Finding the right partner is key to success with low-volume molding. Ask these questions:

1. Do they offer rapid tooling (under 4 weeks)?
2. Can they handle secondary operations (painting, assembly)?
3. What materials can they process?
4. Do they have experience in your industry?
5. Can they help optimize your design for manufacturability?

Our CNC machining service team includes experts who can help with every step of your project.

Common Mistakes to Avoid

Many first-time users make these mistakes:

• Ignoring draft angles – leads to stuck parts and damaged tools
• Designing walls too thin – causes warping and strength issues
• Skipping mold flow analysis – results in air traps and sink marks
• Over-complicating part geometry – drives up tooling costs unnecessarily

Materials Selection Guide

Choosing the right material is critical. Here’s what works best in low-volume production:

Our Swiss machining specialists can help with any high-precision features your parts might need.

Case Study: Medical Device Success

A medical device startup needed 500 prototype housings for FDA testing but couldn’t afford traditional tooling.

The Challenge:

• Needed parts identical to production quality
• Required biocompatible materials
• Had a tight 3-week deadline
• Limited budget of $15,000 total

Our Solution:

• Aluminum tooling with optimized cooling channels
• Medical-grade ABS with proper certifications
• Single-cavity tool with efficient runner system

Results:

• Delivered 500 parts in 17 days
• Total cost: $12,700 (versus $68,000 quoted by traditional molder)
• Parts passed all testing requirements
• Customer proceeded to clinical trials on schedule

Get Started With Your Low-Volume Project

Low-volume injection molding bridges the gap between prototyping and mass production. It gives you:

• Production-quality parts without the high costs
• Fast turnaround times to keep projects moving
• Design flexibility to make changes as needed
• No minimum order requirements – get exactly what you need

If you need help with your next project, our 5-axis machining capabilities ensure we can create even the most complex mold tools with precision.

Ready to learn more? Contact us today to discuss your low-volume injection molding needs!