3D Printing: A Viable Solution for Small-Series Production?

3D printing has revolutionized the way we design and manufacture products. Initially used mainly for rapid prototyping, it has now become a realistic alternative to traditional manufacturing for limited production runs. But is additive manufacturing truly suited for serial production?

At AQ-Tech, a multidisciplinary engineering office specialized in mechanical design, electronics, and technical textiles, we use several 3D printing technologies daily to accelerate product development and validate functional solutions. Here’s our insight into how additive manufacturing can support small and medium-scale production.

1. The Main 3D Printing Technologies

“3D printing” is a broad term encompassing all additive manufacturing processes — building objects layer by layer, as opposed to machining which removes material. Each technology has its own advantages, limitations, and ideal use cases.

Fused Deposition Modeling (FDM)

FDM is the most common technique. A plastic filament (PLA, ABS, or PETG) is heated and extruded layer by layer to form the part. It’s affordable, accessible, and great for quick concept testing. However, surface quality and precision are limited. FDM is perfect for early-stage prototypes and mechanical trials.

Selective Laser Sintering (SLS) & Multi Jet Fusion (MJF)

These industrial-grade processes use powdered polymers (such as PA12) fused by laser or heat. SLS and MJF deliver high mechanical strength, good repeatability, and attractive finishes. The HP MJF process adds a binding agent that improves surface quality and density. This makes it one of the best options for functional parts and small-scale series.

Stereolithography (SLA)

SLA solidifies a liquid resin layer by layer using UV light. It offers outstanding surface finish and fine detail, ideal for design models or presentation prototypes. However, parts remain fragile, making it unsuitable for structural testing. At AQ-Tech, we use SLA to produce masters for vacuum casting or aesthetic mock-ups.

Other Technologies

Other methods such as PolyJet or metal fusion are available for advanced applications but remain more expensive and less suited to agile product development.

2. Why Consider 3D Printing for Production?

Traditional industrialization requires heavy investments: tooling, mold design, and production setup. For startups and SMEs, these constraints often delay product launches and increase financial risk.

An injection mold can cost anywhere from €5,000 to €100,000 and take 3–6 months to complete. By contrast, 3D printing allows production within days, without tooling, and enables quick design updates between batches — an ideal approach for evolving products or pre-market validation.

As we emphasize in our multitechnical projects, flexibility is key. Additive manufacturing gives companies the agility to test, iterate, and scale when market traction is proven.

3. How to Produce with Additive Manufacturing

Before launching additive production, it’s essential to ensure that the part’s geometry, material, and tolerances are compatible with the chosen process. Oversized parts or those requiring micrometric accuracy are better suited to traditional machining or molding.

For small batches (10–500 units), MJF offers the best balance between quality, cost, and lead time. We regularly produce short runs using this process — for example, the Freeside product by ActivMotion — achieving strong, visually clean, and cost-effective parts.

A slight dimensional variation (a few tenths of a millimeter) should be expected, but this remains acceptable for most consumer and industrial applications. For handheld or wearable devices, 3D printing has proven to be a highly reliable solution.

+ AQ-TIPS

• Review your part’s design before selecting the printing method.
• Work with an experienced engineering partner to optimize mechanical and visual performance.

4. Intermediate Solutions Between Prototype and Production

Between one-off prototyping and full-scale manufacturing, several hybrid techniques provide the perfect compromise between cost, quality, and flexibility.

Vacuum Casting

Vacuum casting (or silicone molding) uses an SLA master part to create a silicone mold. The mold is then used to reproduce parts by casting polyurethane resin. Each mold allows around 15 replications and produces parts that look and perform like injection-molded ones. It’s an ideal choice for batches of 10 to 100 units.

Injection Using 3D-Printed Molds

With modern high-temperature resins, it’s now possible to 3D print injection mold cavities. This drastically reduces tooling costs and enables small-scale injection runs — perfect for agile industrialization and market validation.

5. In Summary

3D printing is not meant to replace large-scale plastic injection, but it has become an essential step in modern hardware development. It enables faster iterations, shorter go-to-market cycles, and smarter resource use.

At AQ-Tech, we integrate additive manufacturing into every project stage — prototyping, pre-series, industrialization, and continuous improvement — combining innovation speed with production reliability.

Contact our team to discuss your next project and explore the right production strategy for your product!