MANUFACTURING & DESIGN GUIDE

Material & Process Selection

Choosing the right path for your project can be complex. This guide breaks down the key decisions to help you balance cost, speed, and performance.

Step 1: Choose Your Manufacturing Process

The best process depends on your project's stage, required quantity, and part geometry.

3D Printing

Best for speed and geometric complexity. Ideal for early-stage prototypes, form-fit checks, and highly complex or organic shapes that are impossible to machine. The best choice for quantities of 1-10.

CNC Machining

Best for high-precision parts and functional prototypes in production-grade materials. Ideal when tight tolerances and superior surface finish are required. The best choice for quantities of 1-200.

Injection Molding

Best for production at scale. Offers the lowest per-part cost but requires a significant upfront investment in tooling. The only choice for quantities of 5,000 to 1,000,000+.

Step 2: Choose Your Material Based on Key Properties

If you need...

General Purpose Prototyping: Choose CNC Machined ABS or 3D Printed Nylon (SLS/MJF).
Strength & Stiffness: Choose CNC Machined Aluminum or Stainless Steel. For plastics, choose glass/carbon-filled Nylon or PEEK.
Toughness & Impact Resistance: Choose CNC Machined Polycarbonate or ABS.
Flexibility (Rubber-like): Choose 3D Printed TPU or Molded Silicone/TPE.
Optical Clarity: Choose CNC Machined and Polished Acrylic (PMMA) or Polycarbonate.
Heat Resistance: Choose CNC Machined Aluminum, PEEK, or Ultem™.

A sample board of different engineering plastics, showing the variety of material choices

Material Selection FAQ

How do I choose between two similar materials, like ABS and Polycarbonate?

Look for the key differentiating property. Both are strong thermoplastics, but PC has vastly superior impact strength. If your product is likely to be dropped or hit, the extra cost of PC is worth it. If not, the lower cost and easier processing of ABS make it the better choice.

What is the most cost-effective manufacturing process?

It completely depends on the quantity. For a single part, 3D printing is cheapest. For 100 parts, CNC machining is often cheapest. For 10,000 parts, injection molding is by far the cheapest on a per-part basis, even after accounting for the high tooling cost.

Can you help me select a material?

Yes. Our team of application engineers is here to help. If you upload your design and tell us about its functional requirements (e.g., "it needs to hold 5kg," "it will be used outdoors," "it needs to be clear"), we can provide expert recommendations on the best material and process for your budget and timeline.