Low Volume vs High Volume Injection Moulding: Choosing the Right Production Strategy

Selecting the appropriate production volume is one of the earliest — and most financially significant — decisions in any plastic manufacturing program. The choice influences tooling investment, unit cost, scalability, and overall risk.

While injection moulding is often associated with mass production, modern tooling strategies make it viable across a much broader range of volumes than many companies realise.

Understanding when to prioritise flexibility versus long-term efficiency helps manufacturers align production with real market demand.

What Is Low Volume Injection Moulding?

Low volume production typically ranges from several hundred to a few thousand parts. It is commonly used when companies need functional components without committing to large upfront tooling investments.

Common Use Cases

• Product validation
• Pilot manufacturing
• Bridge production
• Niche market products
• Controlled product launches

Advantages

• Lower initial tooling cost
• Greater design flexibility
• Reduced financial risk
• Faster route to market

Trade-Offs

• Higher per-part pricing
• Limited economies of scale

What Defines High Volume Injection Moulding?

High volume manufacturing focuses on maximising efficiency once demand is established. Production often reaches tens or hundreds of thousands of parts — sometimes more.

Advantages

• Lowest cost per unit
• Highly repeatable quality
• Strong long-term margins
• Automation opportunities

Trade-Offs

• Higher upfront tooling investment
• Less flexibility for late design changes

The Tooling Strategy Behind Each Approach

Tool design typically reflects expected production volume.

Low Volume Tools

• Often aluminium
• Faster to machine
• Lower upfront investment

High Volume Tools

• Usually hardened steel
• Built for durability
• Support consistent long-term output

Selecting the wrong tool for your demand profile can inflate costs unnecessarily.

When Should You Transition to High Volume?

The shift usually makes sense once demand becomes predictable.

Indicators include:

• Stable sales forecasts
• Growing order frequency
• Confirmed product-market fit
• Pressure to reduce unit cost

At this stage, investing in production-grade tooling often improves profitability.

A Hybrid Strategy Many Manufacturers Use

Some companies intentionally begin with lower-cost tooling before upgrading to hardened production tools.

This phased approach allows teams to validate design and demand before scaling aggressively.

Design Still Matters — Regardless of Volume

Whether producing hundreds or hundreds of thousands of parts, manufacturable design remains essential.

Strong DFM reduces risk across every stage of production.