Low Volume Manufacturing

Low Volume Manufacturing is a practical method choice when you need the right balance of performance, finish, and cost for functional parts.

Low Volume Manufacturing Without High Risk or High Cost

Low volume manufacturing is the ideal solution when you need professional-grade parts without committing to the expense, delays, or risk of mass production. At Mitchell & Son Additive Manufacturing, we specialise in producing short-run components that are functional, durable, and cost-effective—whether you need one part or a few hundred.

Traditional manufacturing methods often require tooling costs that can run into thousands of pounds before a single part is produced. That approach makes sense for large production runs, but it is rarely practical for prototyping, legacy parts, specialist components, or niche products. Low volume manufacturing removes that barrier by using advanced 3D printing technologies to produce parts directly from digital designs.

This approach allows you to validate your design, test real-world performance, and refine your product without financial exposure. If changes are required, they can be made quickly in CAD and re-printed without starting again from scratch. That flexibility is critical for businesses that need agility, especially in early-stage product development.

Material selection is also a key advantage. We work with engineering-grade plastics such as ABS, PETG, and ASA, selecting materials based on strength, durability, UV resistance, and finish. We do not apply a one-material-fits-all approach. Instead, we ask practical questions about how the part will be used, where it will be installed, and what stresses it will experience over time.

Low volume manufacturing is also well suited to replacing discontinued or obsolete parts. Many customers come to us with components that are no longer available, where traditional suppliers require full tooling just to reproduce them. By reverse-engineering from an existing sample, we can recreate the part accurately and manufacture only what is needed.

Every project is handled with a focus on function, longevity, and value for money. From CAD design through to printing and optional post-processing, our goal is simple: deliver reliable parts without unnecessary complexity or cost.

From CAD to Finished Parts: A Practical Manufacturing Process

Low volume manufacturing works best when design, production, and finishing are treated as a single, integrated process. At Mitchell & Son, we manage the entire workflow—from initial concept through to finished components—ensuring quality and consistency at every stage.

The process begins with a 3D model. If you already have one, we can work directly from it. If not, we can design or replicate a part using CAD, including reverse-engineering from a physical sample where required. This is a critical step, as accurate digital modelling ensures dimensional accuracy and repeatable results.

Once the design is finalised, we move into material selection and print setup. Factors such as infill percentage, wall thickness, and layer orientation are carefully chosen based on how the part will be used. Components that experience load, movement, or repeated stress require different settings compared to cosmetic or ornamental items.

Unlike mass manufacturing, low volume production allows us to optimise each print rather than relying on generic settings. This ensures parts are strong where they need to be, without unnecessary material usage that increases cost.

After printing, optional post-processing can be applied. This may include sanding, priming, resin coating, or surface finishing to improve strength, appearance, or wear resistance. These steps are particularly useful when parts are visible, customer-facing, or subject to regular handling.

The result is a manufacturing process that is flexible, transparent, and controlled. You are not locked into long lead times or minimum order quantities, and you retain the ability to adapt as your requirements evolve.

Ideal Use Cases for Low Volume Manufacturing

Low volume manufacturing is not a compromise—it is often the most sensible manufacturing choice. It is particularly well suited to applications where flexibility, speed, and cost control are essential.

One common use case is prototyping and product development. Before committing to large-scale production, businesses need to test form, fit, and function in real-world conditions. Producing small batches allows for iterative improvement without financial risk.

Another key application is the replacement of discontinued or obsolete parts. Machinery, vehicles, and equipment often rely on components that are no longer produced by original manufacturers. Low volume manufacturing allows these parts to be recreated accurately, extending the life of valuable assets.

Custom fixtures, jigs, and tooling are also ideal candidates. These items are rarely produced in large quantities, yet they must be strong and dimensionally accurate. 3D-printed solutions can be designed specifically for their task, improving efficiency while keeping costs low.

Finally, low volume manufacturing supports niche and specialist products. Whether you are serving a small market or launching a limited-run product, this approach allows you to manufacture only what you need, when you need it.

A Smarter Alternative to Injection Moulding

Injection moulding has its place, but it is not always the right starting point. Tooling costs, long setup times, and inflexible production runs make it unsuitable for many projects—particularly during early development.

Low volume manufacturing offers a smarter alternative. By producing parts directly from digital files, you eliminate tooling entirely. This dramatically reduces upfront costs and allows production to begin immediately.

Design changes are also far easier to implement. Instead of modifying expensive moulds, adjustments are made in CAD and applied to the next print run. This enables continuous improvement without penalty.

For many customers, low volume manufacturing bridges the gap between concept and mass production. It provides real-world data, customer feedback, and proven designs before committing to large-scale tooling. In many cases, it removes the need for injection moulding altogether.

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