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Low Volume Production with Injection-Molding Quality using DLP Technology

Traditional high-volume manufacturing is under pressure. Geopolitical conflicts, material shortages, pandemics, transportation disruptions, and the growing need for customization are all straining supply chains and inventory management.  

To stay competitive, businesses need innovative solutions - and low volume manufacturing is increasingly popular. 

For low volume production, additive manufacturing offers a cost-effective solution, addressing some of the limitations of traditional manufacturing: 

  • Avoid the high costs and long lead times associated with tooling. 
  • Print on demand, supporting small volume manufacturing. 
  • Create complex designs in a single print, reducing assembly time.
  • Bring production in-house, mitigating supply chain disruptions. 
Manufacturing

Low Volume Production is the Future of Manufacturing

Low volume manufacturing offers a flexible and cost-effective alternative to the high-volume model. However, traditional methods can come with high setup and tooling costs, and manufacturers are looking for more economically viable options for short production runs.

Think 3D printing can’t achieve high accuracy? You haven’t met Origin Two.

3D printing in manufacturing has come a long way, with many technologies now capable of meeting average production standards for accuracy, tolerance and surface finish.

However, for the most stringent requirements, these technologies often fall short. Meeting these demanding standards require specialized technology engineered for such applications. 

The Origin Two system, developed based on customer feedback, in combination with its validated Origin Cure post-processing solution, excels in:
•    High accuracy: Achieving tolerances as tight as 50 microns for specific applications.
•    Repeatability: Consistent print results across builds and printers, maintaining tight variation levels.
•    Smooth surface finish: Comparable to injection molding.

Tests conducted on multiple Origin printers demonstrated the repeatability of the printing process, showing consistent results without the need for recalibration, across different build heads and printers. This proves that Origin Two is a true injection-molding alternative for short production runs of high accuracy parts.

Download the Repeatability White paper

Depending on what you need to print and the quantities, , 3D printing brings significant savings for low volume production over injection molding, even if the required technology comes at a higher price point than the average systems. 

“Stratasys has helped us optimize accuracy and repeatability for connectors that require +/- 50 micron accuracy, demonstrating the possibilities of using additive manufacturing to produce part volumes in the tens of thousands.”

The Importance of Curing

Achieving the best results doesn't stop at printing. Proper curing is essential to ensure parts reach and retain their accuracy and performance.  

The Origin Cure™ system is engineered to lock in accuracy, repeatability and detail of your printed parts. It complements the Origin DLP process to deliver: 

  • Consistent quality: Reduce variability with uniform curing for all parts. 
  • Fast processing: Complete curing quickly and keep production lines moving. 
  • Ease of use: Set up and operate simply, integrating seamlessly into your workflow.

Real-World Success Stories in Low-Volume Manufacturing

"Every day we discover new Origin applications and materials, allowing us to remain at the forefront of design and development, and to innovate in ways that were impossible yesterday."

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Mechanical and finish quality comparable to IM

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TE Connectivity needed a 3D printing solution that can process highly accurate connectors, consistently, and fast. Only Stratasys Origin met those requirements.

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As well as tooling and functional prototypes, H&T Presspart use Stratasys Origin to print user-specific adapters for breathing simulation equipment, at a cost saving of 80%.

Connector Prototype

Techno chose Origin DLP to help develop fully functional prototypes faster and more flexibly, while meeting the required electrical-mechanical regulations.

FAQ

High-mix low-volume manufacturing involves producing a diverse range of products in small quantities. It’s particularly beneficial for companies that need to offer a variety of customized products without the  costs associated with traditional high-volume manufacturing. As consumers prefer more customized or personalized products, and companies look for reducing costly inventory, the need for economically viable high-mix low volume manufacturing methods has been growing. 

Low volume manufacturing refers to the production of parts in small quantities. It is often used for prototyping, custom parts, and short-run productions, providing a cost-effective alternative to traditional high-volume manufacturing.

Low volume manufacturing offers many advantages over traditional high-volume manufacturing because it eliminates the need for expensive tooling, reduces upfront costs, and offers greater design flexibility. It allows for on-demand production, minimizing inventory and waste. Additionally, it enables faster prototyping and quicker response to market changes, making it a more efficient and cost-effective solution for small volume production.

Discover how you can meet your low volume manufacturing needs

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