Prototype to Production Australia
Start with 1 prototype. Confirm your design. Scale to production. The same managed supply service supports you at every stage — no minimum order, no starting over as volumes grow.
The Prototype to Production Journey
Every production part started as a prototype. Rapid Manufacturing supports your project at every stage of development.
Prototype
Prove concept, verify fit and function
First article parts machined to your drawing. DFM analysis identifies design improvements before committing to higher quantities.
Development
Engineering validation, testing
Design iterations machined quickly from updated drawings. Same supplier, same managed process. No tooling cost.
Pilot Production
First customer units, market validation
Confirmed design moves to pilot production. Pricing improves with quantity. Inspection plans formalised.
Production
Ongoing supply, commercial quantities
Production supply with scheduled releases. Supplier qualifications retained. Transition to casting or moulding advised if volume justifies tooling.
How Quantity Affects Part Cost
Setup cost is amortised as quantity increases. Here is indicative pricing for a medium-complexity aluminium CNC machined part.
| Quantity | Indicative Unit Price | Stage | Notes |
|---|---|---|---|
| 1 off | $800–$1,500 | Prototype | High setup amortisation, DFM included |
| 5 off | $350–$600 | Development | 50–60% cost reduction vs 1 off |
| 25 off | $180–$300 | Pilot | Tooling and fixturing amortised |
| 100 off | $100–$180 | Production | Optimised cycle times, batch inspection |
| 500 off | $60–$120 | Volume | Dedicated supplier allocation |
| 1,000+ | Consider casting | High Volume | Die casting may be more economical |
Indicative pricing AUD ex GST. Actual pricing depends on geometry, material, tolerances, and finish. Request a quote for accurate pricing.
Why Rapid Manufacturing for Prototype to Production?
No Minimum Order at Any Stage
Start with 1 part and scale without ever being told your order is too small. Prototype, development, pilot, and production quantities all managed through the same service.
DFM at the Prototype Stage
Free design for manufacturability analysis with every prototype quote. Catching design issues at prototype stage costs nothing. Catching them at production tooling stage costs tens of thousands.
Supplier Continuity
We aim to keep the same qualified supplier from prototype through production. No re-qualification, no tooling recreation, no first article re-inspection from scratch on each order.
Bridge Production Available
Order machined bridge production parts while your injection mould or die cast tooling is being made — keep selling, keep shipping, no gap in supply.
Process Transition Advice
At the right quantity, we advise on transitioning from machining to injection moulding or die casting. We handle the tooling procurement and supply the production parts.
Repeat Order Efficiency
Retained drawings, supplier records, and inspection plans mean repeat orders are fast and accurate. No re-submission, no re-quoting from scratch — just a purchase order.
Prototype to Production FAQ
Can I start with just one prototype and then scale to production?
Yes. This is one of the most common journeys our customers take. Start with a single prototype — we produce it to your drawing, inspect it, and deliver it. When your design is confirmed, order 5, then 50, then 500. We maintain your drawing, supplier qualifications, and tooling offsets between orders, so each production release runs without starting from scratch. No minimum order at any stage of the process.
What is low volume manufacturing and when does it make sense?
Low volume manufacturing refers to production runs of 1–500 parts where the cost of dedicated tooling (injection moulds, die casting dies) cannot be justified. CNC machining is the dominant process for low volume production because it requires no dedicated tooling — each part is machined directly from your drawing. Low volume machined parts make economic sense for engineering prototypes, spare parts, replacement components, niche products, and initial market-entry quantities before committing to high-volume tooling.
How does pricing change from prototype to production quantities?
Prototype pricing reflects the high per-part setup cost when producing 1–5 parts. As quantity increases, setup cost is amortised over more parts, reducing per-unit cost significantly. Going from 1 part to 10 parts typically reduces per-unit cost by 30–50%. Going from 10 to 100 parts often reduces it by another 40–60%. Going from 100 to 1,000 may trigger a process change (e.g. from machining to die casting) that reduces cost by another 50–80%. We advise on process transitions as your volumes grow.
At what quantity should I switch from CNC machining to injection moulding or die casting?
For plastic parts, the crossover from machined prototypes to injection moulded production typically occurs at 500–2,000 parts — depending on part complexity, material, and mould cost. For aluminium, die casting becomes competitive at 1,000+ parts for simpler geometries. Below these quantities, CNC machining is almost always more economical. We can provide pricing at multiple quantities so you can make an informed decision on tooling investment versus machining cost at your projected volumes.
What is bridge production and how does it help?
Bridge production is machined production while your dedicated tooling (injection mould, die cast die) is being made. Rather than waiting 8–16 weeks for tooling and shipping no product, you machine 50–200 parts from your finalized design to fulfill initial orders. When the tool is ready, you switch to the higher-volume process. Rapid Manufacturing provides bridge production as a standard offering — we machine your bridge quantity while you progress tooling procurement in parallel.
Will the same supplier make my prototypes and production parts?
We aim to maintain supplier continuity from prototype through production wherever possible. The same supplier already has your program loaded, tooling offsets established, and inspection plans in place. This eliminates transition risk and reduces production lead time. For very high-volume orders requiring different equipment or capacity, we will introduce a production-capable supplier and manage a formal transition with first article inspection.
Can Rapid Manufacturing supply small batch production parts on a regular schedule?
Yes. Many customers release small batch orders on a monthly or quarterly schedule — 10–100 parts at a time to match their sales or service demand. We maintain your drawing and supplier qualifications between releases, so each order is fulfilled efficiently without re-qualifying. Blanket purchase orders with scheduled releases, kanban replenishment, and safety stock arrangements are all supported.
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Start with a single prototype. Scale to production. Free DFM analysis included with every quote — no minimum order required.
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