Which Manufacturing Process Is Right for Your Part?

Choosing the right manufacturing process can significantly impact your part’s cost, quality, and production timeline.

Instead of evaluating every possible option at once, this guide helps you narrow it down quickly based on two key factors:

1. How many parts you need per year
2. What your part requires—complex geometry, standard features, or extreme precision

From there, you can identify the best-fit process for your application, or download our Process Flowchart for easy viewing.

Not sure where to start? We’ll help you choose the right process for your part.

Prototyping

Best for early-stage design validation, iteration, and speed

At the prototyping stage, the goal is to move quickly, test designs, and iterate efficiently.

If you need quick, low-cost prototypes:

• SLA — Low cost with fast turnaround times

If you need functional, production-like prototypes:

• Urethane Casting — Ideal for multiple prototypes with production-like materials
• FDM — Strong, production-ready prototypes with quick turnaround
• HP Multi Jet Fusion — Durable prototypes with excellent surface finish
• Carbon DLS — Functional prototypes with production-grade strength and accuracy

If your part requires extreme precision or micro-scale features:

• Micro DLP — Ideal for highly precise parts used in medical, electronics, and aerospace applications

100–1,000 Parts Per Year

Early production that balances cost, flexibility, and performance

At this stage, you're moving beyond prototyping into low-volume production, where both cost and part performance matter.

If your part is complex or highly detailed:

Carbon DLS — Complex parts with excellent surface finish

HP Multi Jet Fusion — Durable parts with fine detail

If your part is more standard or cost-sensitive:

FDM — Cost-effective, production-ready parts

Urethane Casting — Low-volume production with production-like materials

If your part requires extreme precision:

Micro DLP — Ideal for micro-scale production parts

1,000–10,000 Parts Per Year

Scaling production with improved consistency and efficiency

As volumes increase, repeatability, tighter tolerances, and process efficiency become more important.

If your part is complex or requires tight tolerances:

• Carbon DLS — Complex geometries with strong mechanical properties

• 5-axis CNC machining — Precision machining for complex, multi-angle parts

• Electrical Discharge Machining (EDM) — Intricate parts in hard metals

If your part is more standard or repeatable:

• HP Multi Jet Fusion — Fast, consistent production
• Injection molding — Scalable, repeatable plastic parts
• 3- or 4-axis CNC machining — Reliable machining for standard geometries

10,000–50,000 Parts Per Year

High-volume production with a focus on efficiency and cost-per-part

At higher volumes, optimizing cost-per-part and ensuring consistent quality becomes critical.

If your part is complex:

• 5-axis CNC machining — Advanced machining for complex geometries
• Carbon DLS — High-accuracy, production-grade parts
• Electrical Discharge Machining (EDM) — Precision machining for intricate designs

If your part is more standard:

• 3- or 4-axis CNC machining — Efficient machining for standard parts
• Injection molding — High-quality, repeatable production

50,000+ Parts Per Year

Full-scale production focused on efficiency, repeatability, and cost optimization

At this scale, manufacturing processes must support high throughput and long-term cost efficiency.

If your part is complex:

• 5-axis CNC machining — Precision machining at production scale
• HP Multi Jet Fusion — High-volume, durable plastic parts
• Carbon DLS — Complex parts with excellent accuracy and surface finish
  
  

If your part is more standard:

• Injection molding — Best for high-volume, repeatable plastic parts
• 3- or 4-axis CNC machining — Reliable machining with tight tolerances

How to Choose the Right Process

Volume is just the starting point. Your part requirements matter.

While volume is a key driver, selecting the right manufacturing process also depends on:

• Part geometry and complexity
• Material requirements
• Tolerance and surface finish needs
• Timeline and speed to market
• Cost targets

In many cases, the best solution involves combining multiple processes. such as prototyping with additive manufacturing before transitioning to machining or injection molding for production.

Your Full-Service Partner

From Prototype to Production

You get a partner that helps you evaluate your part requirements and select the right manufacturing process from the start.

From early prototyping through full-scale production, your project is guided by engineering expertise and a consultative approach. ensuring the right balance of cost, quality, and performance.

Not Sure Which Process Is Right?

Choosing the wrong process can lead to unnecessary cost, delays, and performance issues.

Get expert guidance on the best manufacturing approach for your part today.