Orion Design
Interactive tool

Manufacturing Payoff Visualiser

Compare total cost curves across common prototyping and production methods. Adjust setup and unit assumptions, then inspect which route wins at your target volume and where crossover points occur.

Inputs

Model assumption: total cost = setup cost + (unit cost x quantity). Use this as an early decision aid, not a final supplier quote.

Results

Quick answer

Injection moulding becomes cheaper when the tooling cost is repaid by the lower unit cost.

Break-even volume = tooling cost / (prototype unit cost - moulded unit cost)

Using the default assumptions against 3D printing: GBP6,500 / (GBP18 - GBP0.70) = roughly 376 units.

Worked example

If a part costs GBP18 to 3D print and GBP0.70 to mould, but the tool costs GBP6,500, the cheapest route depends entirely on realistic demand and how confident you are that the geometry is stable enough to tool.

How this calculator works

The lines show total cost, not unit cost. That matters because early manufacturing decisions are usually distorted by low setup options looking cheaper at the start, while tooled routes only win once volume justifies the upfront commitment.

  • Use low setup routes for learning and early uncertainty.
  • Use bridge routes when demand is growing but tooling still feels risky.
  • Use injection moulding when volume and design stability support the investment.

FAQ

When should a team tool up for injection moulding?

Only when projected demand, part maturity, and cash-flow tolerance justify the tooling commitment, not just when unit cost looks attractive.

Why compare total cost rather than unit cost?

Total cost reveals when low setup methods stop being the sensible choice and when high-commitment routes finally become economically defensible.

How this calculator works

Early-stage estimate, not final quotation

This calculator turns the assumptions you enter into an early engineering or commercial estimate. It is most useful for comparing options, surfacing trade-offs, and deciding what needs deeper validation next.

Source and Attribution

This engineering calculator and supporting analysis were created by Orion Design. Use the result as an early decision aid, then confirm the numbers with suppliers, manufacturing partners, and project-specific data.