Development of Low-Volume Injection Molding

Injection molding a useful production method which enable manufacturers to produce identical parts with consistent quality and characteristics in high volume. In injection molding process, a pressurized nozzle shoots molten plastic into a metal mold to make the parts cool and be ejected quickly. When the parts are ejected, the press closes and the operation repeats. There are many plastic products in our daily life like bottles caps, cart parts and gears are produced by injection molding. In the past, injection molded parts needed to be produced in high volume to cover the high setup costs. It will cost even ten of thousand of dollar and weeks to months to build a hardened steel mold. Injection molds are durable which allow manufacturer to recoup their investment and also lower the cost per unit. As market evolve, small batch products are increasingly needed. More and more plastic businesses are looking at low-volume injection molding. Customer expectations are going for lower volume which allows business to develop new products and markets with less risk. Manufacturers adapted their operation to take advantages of new methods. Low volume injection molding is one of those methods. Low volume injection molding is a priority for plastic businesses in small or medium production.

Why Low Volume Molding

Plastic parts manufacturing is a fast-paced business but plastic parts production is not a quick process. Plastic parts manufacturing is a complex process to start with. Depending on the plastic parts design, every design needs a customized injection mold to get right tolerance, finish and functionality. It also takes time to build injection molds. Some low volume plastic parts manufacturing manufacturers order the plastic molds or parts directly from suppliers to save expenses. Here’s why many businesses choose low-volume injection molding:

Cost-Effective for Small Runs

• Traditional high-volume injection molding requires expensive steel molds and large production runs to justify the cost.
• Low-volume molding uses aluminum or soft tooling, significantly reducing upfront costs.
• Ideal for rapid prototypes, pilot runs, or limited product releases without high financial risk.

Faster Lead Times

• Low-volume molds are easier and quicker to manufacture than high-volume steel molds.
• Parts can be produced in weeks instead of months, accelerating product development.
• Perfect for market testing or design validation before committing to mass production.

Design Flexibility

• Low-volume injection molding allows quick modifications to molds as designs evolve.
• Iterations can be made without significant cost or delays, enabling better product optimization.
• Supports a wide variety of materials and colors, giving designers more creative freedom.

Functional and High-Quality Parts

• Unlike 3D printing or other prototyping methods, low-volume injection molding produces real, functional parts with the same mechanical properties and surface finish as mass-produced parts.
• Ideal for testing fit, form, and function in real-world applications.

Ideal for Market Testing

• Produce small batches for market feedback, user testing, or pilot programs.
• Helps companies validate demand before investing in high-volume production.

Cost and Time Efficient

Injection Molding Process: Traditional Molding vs. Low-Volume Injection Molding

Like regular plastic production, low volume injection molding process needs a 2D or 3D design and use CNC machining, EDM, wire cutting, polishing etc. processes to create the molds. The key difference is the mold lifespan, low-volume injection molds use aluminum or low grate steel to as the mold materials, which cannot withstand much many times of injection press. Traditional molds made out of hardened steels can withstand 100,000+ molding cycles that is enough not only for low volume injection molding but also mass production. Soft steel is better to be work with compared to hardened steel which makes the whole process easier and faster, it is good for Low volume injection molding, and it is cost-effective method.

Comparison Table

Summary

• Traditional molding is best for large-scale, long-term production where low per-part cost is critical.
• Low-volume injection molding is ideal for fast prototypes, small batches, and design testing, offering speed, flexibility, and lower upfront cost.

What is low volume Manufacturing, and Advantages and Disadvantages of Low-Volume Molding

Low-volume manufacturing (LVM) refers to the production of a small quantity of parts or products, typically ranging from dozens to a few thousand units per run, depending on the industry and production method. Unlike traditional high-volume manufacturing, which focuses on mass production, low-volume manufacturing emphasizes flexibility, speed, and cost-efficiency for small batches.  low volume injection molding is one kind of LVM process,

Advantages

it has lower tooling investment. Hardened steel production mold is a high investment, small and medium business may not able to adapt to the fast-paced environment if they are in limited budget. Low volume injection molding is flexible and allow them to work around their finances. Another advantage of low volume injection molding is the short lead time that leads to faster production. Low volume injection molding takes around 3-4 weeks for manufacturers to get ready. This allows manufacturers to launch their new products to the market faster and get some returns immediately from their business investment.

What are the disadvantages of this Molding

The main disadvantage of low volume plastic injection molding is that is it not a method for large mass production quantities. It is for suitable for companies which produce thousands of parts at a quick rate. Low volume injection molding accustomed for small to medium businesses.

Low Volume Molding Services at TEAM RAPID

At TEAM RAPID, we specialize in low-volume injection molding services that help businesses bring products from concept to reality quickly and cost-effectively. Whether you need prototypes, pilot runs, or small-batch production, our team delivers high-quality, functional parts with fast turnaround times.

Applications of Our Low-Volume Molding Services

• Product prototypes and R&D testing
• Pilot production runs for market validation
• Custom or limited-edition parts
• Consumer electronics, automotive, medical, and industrial components

Get Started with TEAM RAPID

Ready to bring your design to life? Contact TEAM RAPID today to discuss your low-volume molding project, request a quote, or get professional guidance on the best material and process for your parts.

📞 Call us: +86 0760 8850 8730
📧 Email us: [email protected]

Frequently Asked Questions (FAQs)

How many parts qualify as “low-volume”?

While it varies by industry and project, low-volume production generally refers to 50–10,000 parts per run. Anything beyond that typically falls under medium- or high-volume manufacturing.

What materials can be used for low-volume injection molding?

We support a wide range of thermoplastics, including:

• ABS, PC, PP, PE, Nylon, POM
• Flexible and engineering-grade plastics
• Custom color options and blends

Can I make design changes during low-volume production?

Yes! Low-volume injection molding uses aluminum or soft tooling molds, making it easy to modify or iterate designs between runs without high costs.

Are low-volume molded parts the same quality as high-volume parts?

Yes. Parts produced with low-volume molding are functional and durable, with similar mechanical properties, fit, and surface finish as high-volume production. It is suitable for form, fit, and functional testing.

What industries use low-volume injection molding?

Common industries include:

• Consumer electronics
• Automotive and automotive components
• Medical and healthcare devices
• Industrial and mechanical parts
• Custom or limited-edition products