[Small-Lot & Prototype Press Parts] Deciding When a Die Is Worth Making for Low-Volume Production

For prototype or small-lot parts, have you ever hesitated over whether it's worth making a die for such a small quantity?

Making a die makes mass production easier, but when quantities are low, the die cost burden becomes heavier. That said, choosing die-less processing isn't always the advantageous option either — as production volume increases, processing time and per-unit cost change as well.

So at what point does it make sense to invest in a die?

This article sets out the conditions to consider when deciding on a production method for prototype and small-lot parts.

Table of Contents

• Why Die Cost Tends to Be a Challenge in Small-Lot Production
• Decision Criteria to Check When Choosing a Production Method
• Three Production Methods That Vary by Condition
• PRESS CRAFT (THAILAND)'s Production System for High-Mix, Low-Volume Manufacturing
• FAQ

Why Die Cost Tends to Be a Challenge in Small-Lot Production

Die press production requires making a die matched to the product shape before production begins. When production volume is high, the die cost can be spread across many products, but for low-volume projects, the initial investment burden per unit becomes larger.

This is especially true for prototypes, parts produced only for a short period, or projects where future order quantities are not yet confirmed — it becomes harder to decide whether a die should be made from the start. This is because, while there is a chance that order quantities will increase, there are also cases where volume does not grow as expected, or where specifications change partway through.

For this reason, in small-lot projects, deciding at what stage to make the initial investment in a die becomes one issue to consider when thinking through the production method.

Decision Criteria to Check When Choosing a Production Method

Whether or not to make a die also cannot be decided by production volume alone. The suitable processing method varies depending on product shape, material and sheet thickness, required precision, production period, and production efficiency.

When comparing processing methods, it helps to organize the following conditions.

Three Production Methods That Vary by Condition

Once the decision criteria are organized, production methods can broadly be divided into "die press," "die-less processing," and "a method combining both."

Die-less processing is easier to consider for prototypes, small lots, or projects where specifications may change and die investment needs to be kept in check. On the other hand, for projects producing a steady volume on an ongoing basis, making a die and press-processing can in some cases improve production efficiency.

In addition, everything doesn't need to be unified into one method or the other. "Combine production," which uses die-less processing for some processes and die press for the rest, is another option — production methods can be combined to suit quantity and shape.

PRESS CRAFT (THAILAND)'s Production System for High-Mix, Low-Volume Manufacturing

In the manufacturing industry, production volumes and order patterns are changing, driven by trends such as high-mix, low-volume production. As a result, more projects are becoming difficult to accommodate with a conventional production method alone.

Building on die design and manufacturing, along with press processing technology developed over many years, PRESS CRAFT (THAILAND) is expanding what it can support by incorporating new processing equipment.

Rather than committing to a single processing method, the company has a system that can consider the most suitable method based on the production conditions at hand, allowing it to respond to changes in production volume and market needs.

Even at a stage where drawings or specifications are not yet finalized, the company can propose a suitable production method based on the conditions known at that time. Inquiries are welcome.

FAQ

Q: If it's a small lot, is die-less processing always the more suitable option?
A: Not necessarily. The suitable processing method depends not only on quantity but also on product shape, material and sheet thickness, required precision, and production period.

Q: Can prototypes be made with die-less processing first, then switched to die press once production increases?
A: Yes. It's possible to consider using die-less processing in the initial stage, then making a die and transitioning to mass press production once production volume increases.

Q: Can die-less processing and die press be combined for the same product?
A: Yes. "Combine production," which uses die-less processing for some processes and die press for the rest, can also be proposed.

Q: Can I consult with the company even at a stage where I don't yet know which processing method is suitable?
A: Yes. A production method can be considered by checking the conditions known at that time, such as quantity, shape, material, sheet thickness, and required specifications.