In the rapid prototyping and manufacturing industry, companies have options for low-volume and high-volume production. Low-volume manufacturing is suited to smaller projects. High-volume manufacturing services are the better choice for larger projects looking to benefit from savings brought on by economies of scale.
Companies must consider the right application for their project and debate the benefits of low and high-volume production for their needs. Whether they&#;re releasing new products to the market or scaling manufacturing for existing projects, manufacturers must balance low costs and high quality for success.
Increasing manufacturing volume results in lower unit costs when working with contract manufacturing partners. The type of manufacturing method and manufacturing location also contribute to project costs.
There are several considerations when choosing between low and high-volume manufacturing processes. Additive manufacturing is one of the most popular processes for all volume requirements in rapid prototyping and mass production projects. This gives project managers and manufacturers a viable production process for any volume required, reducing risk while improving the agility of the business.
Here is how additive manufacturing (3D printing) reduces the gap between low and high-volume manufacturing.
When considering your options for low or high-volume manufacturing, it&#;s important to consider several factors relating to cost-effective production. The elements driving costs in rapid prototyping or mass manufacturing are the following.
Let&#;s take a closer look at the differences between low and high-volume manufacturing.
High-volume production is the best option for high-demand products. Companies looking to create and mass-produce prototypes to satisfy demand will get the best value and cost savings from high-volume production practices.
Mass production significantly drops unit costs per component compared to low-volume production processes. For instance, you might pay $500 for a one-off but $.050 for the same item when produced in the hundreds of thousands of units.
A low-volume production strategy is ideal for rapid prototyping projects where a company wants to introduce low-demand products. Low production volumes are generally suited to rapid prototyping projects and limited-edition or customized products.
High-volume mass production is preferred over low-volume for improved cost efficiency while ensuring high quality. This production strategy is less labor-intensive and more efficient, resulting in huge project and manufacturing cost savings.
However, companies looking to produce products in lower quantities may see more benefit from low-volume production. This strategy has a higher degree of flexibility, accommodating a broader range of product designs and projects.
Additive printing, known by its more common moniker, &#;3D printing,&#; is highly adaptable and suitable for low- and high-volume manufacturing projects. 3D printing reduces CAPEX investment requirements for traditional process scaling.
Companies can implement low-volume, high-mix production strategies to improve and increase throughput. 3D printing allows manufacturers to change their business model with the following strategies.
Eliminate the requirement for custom tooling to accelerate manufacturing of revised and new designs. Design engineers can change the original design and experience immediate production of the new product with the desired changes.
3D printers print directly from digital model designs, allowing the immediate production of parts and products on demand. Thus, companies benefit from cost savings since they need to keep less inventory on-site to satisfy market demand.
3D printers can manufacture complex components, consolidating sub-parts to eliminate unnecessary assembly typically required in processes like injection molding. Streamlining manufacturing processes and steps makes 3D printing cost-competitive compared with injection molding.
Increasing volume leads to improvements in manufacturing efficiency. 3D printing doesn&#;t require custom tooling for each component, giving the manufacturer a wide range of products using the same manufacturing equipment. Its high degree of flexibility supports a combination of multiple &#;SKUs&#; or products, thereby increasing manufacturing volume.
With improved automation in manufacturing processes, companies receive better agility and flexibility in locating their operations. The manufacturer can set up their operation closer to the customer, resulting in lower logistics costs and faster customer fulfillment.
Injection Molding
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Injection molding involves creating a mold and injecting melted material into it to make precise parts. It&#;s great for producing small quantities of consistent and detailed components quickly.
CNC Machining
CNC machining uses a computer-controlled machine to carve out intricate parts from solid material. It provides high precision and is useful for making detailed components with exact specifications.
3D Printing (Additive Manufacturing)
3D printing builds objects layer by layer, like stacking blocks. It allows the company to create prototypes and test different designs quickly. Any needed adjustments can be made easily.
Urethane Casting
Urethane casting involves creating a mold and then pouring urethane material into it. It&#;s good for making flexible parts and is cost-effective for small runs of products.
Rapid Prototyping
Rapid prototyping quickly creates physical models from digital designs. This method helps the company test and refine designs quickly before moving to larger production.
Vacuum Casting
Vacuum casting uses a vacuum to fill molds with liquid material, producing high-quality parts with fine details. It&#;s suitable for low volume production and allows for easy changes to the design.
Laser Cutting and Engraving
Laser cutting and engraving use lasers to cut and etch materials with high precision. This method is perfect for creating detailed and complex shapes from various materials.
Die Casting
Die casting involves injecting molten metal into a mold under high pressure. It&#;s efficient for producing small quantities of metal parts with a high level of detail.
Extrusion
Extrusion pushes material through a shaped die to create long, consistent profiles. This method is useful for making continuous shapes and parts in low quantities.
Composite Fabrication
Composite fabrication involves combining materials, like fibers and resins, to create strong and lightweight parts. It&#;s ideal for parts that need to be both durable and light.
Silicon Molding
Silicon molding uses silicone rubber to create flexible molds for low volume production. It&#;s effective for making complex shapes and detailed parts.
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