Small Batch Injection Molding Too Expensive? Save 30% This Way

• Ultra-small batches (<1,000 units)：Abandon steel molds and adopt aluminum or silicone molds, which cost only 1/5 to 1/3 of traditional steel molds and double processing speed. For example, for a 500-unit trial order, the mold cost can be reduced from $11,200 to less than $2,800.
• Medium batches (1,000-5,000 units)：Simplify structural design by eliminating "luxury configurations" such as complex core-pulling and automatic thread stripping, replacing them with manual demolding to cut processing costs by 40%. Merge parting surfaces and use straight cooling channels to reduce CNC processing time by over 30%.
• Near-mass production (5,000-10,000 units)：Choose standard mold bases like LKM, which cost 50% less than custom ones. Use P20 pre-hardened steel (service life up to 100,000 cycles) for cores and cavities instead of high-priced H13 steel, saving 1/3 of material costs.

2. Process Aspect: Reject "One-Size-Fits-All" and Optimize the Entire Production Process

1. Runner system adaptation：Prioritize cold runners in most scenarios, which cost 60% less than hot runners and have modification costs only 50% of hot runners. Hot runners are only cautiously used for thin-walled parts (wall thickness <1.5mm) or transparent parts to avoid insufficient filling.
2. Prototype testing cost control：Strictly limit prototype testing to 3 times or less: the first test verifies basic functions (allowing 10% dimensional deviation), the second adjusts the cooling system (deformation <0.3%), and the third confirms surface quality (Ra≤1.6μm), reducing prototype loss by 40%.
3. Material and parameter optimization：Control regrind ratio at 10%-30% (≤10% for precision parts), use infrared moisture meters to strictly control drying parameters, and reduce scrap rates. Shortening cooling time by 10 seconds per cycle can increase annual output by 15% and amortize unit costs.

3. Supply Chain Aspect: Choose the Right Partners and Control Lifecycle Costs

1. Precise supplier matching：For ultra-small batches, select rapid prototyping factories with strong aluminum mold processing capabilities (10-day delivery); for medium batches, choose regional integrated factories that can reuse inventory standard parts; for high-precision needs, cooperate with professional factories that prioritize small-batch orders.
2. Contract and custody design：Adopt phased payment of "30% deposit + 50% after qualified prototyping + 20% after delivery" to reduce financial pressure. Sign mold custody agreements for free storage by suppliers for 6 months, saving 80% of storage costs compared to building in-house warehouses.
3. Avoid low-price traps：Be wary of suppliers quoting 40% below market average (likely using inferior steel) and reject "zero-modification" promises (minor adjustments in the first test are normal). Prioritize partners who can provide DFM optimization suggestions.