I'm planning a pilot launch of a small batch of devices. Which prototyping method should I choose for accelerated testing of geometry and assembly? Options: 1) 3D printing (any method), 2) CNC milling, 3) injection molding (for plastic). What would you prefer and why? Consider speed, cost for batches up to 50 units, and part strength.
What to prototype with? 3D printing vs. milling vs. casting
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For single units and small batches up to 50 pieces, I’d recommend starting with vacuum casting—it’s the perfect balance between speed and precision. First, print a master model using an SLA printer (with clear or standard photopolymer resin), then cast the parts in polyurethane using a silicone mold. You’ll get parts with properties close to serial plastics (like ABS-like materials), and the cost per unit will be lower than CNC milling or injection molding. Combined with 3D-printed tooling, this approach is both cost-effective and fast—you can have 10–15 identical parts for geometry and assembly testing in just a couple of days.
If the budget is really tight, go with classic FDM printing for the first round. Yes, the strength and surface finish won’t be as good, but it’ll cost around 500–800 rubles per part for batches of 3–5 pieces. Once the geometry checks out, switch to vacuum casting—this way, you’ll refine all assembly nuances and prepare for scaling. CNC milling should be saved for the absolute last resort: for small runs, it’s more expensive than casting, and for complex geometries, 3D printing is still far more convenient.