Low Volume Injection Moulding — 100 to 10,000 Real Parts
Aluminium bridge tooling lets you produce 100 to 10,000 genuine injection-moulded parts in production-grade polymer — at a fraction of hardened-steel tooling cost, and a fraction of the lead time. The right move when you need real product, not prototypes, but don't yet need a million units.
Typical projects start from $500+ · Engineering & business enquiries welcome · Upload CAD, STEP & STL files for review
Manufactured in
Sydney, Australia · Quality-checked on every job
Why Forge Labs
Why bridge tooling beats prototyping and full production
The right choice when 3D printing is too expensive and steel production tooling is too risky.
100 to 10,000 Parts
The sweet spot between vacuum casting (1–50 parts) and full production injection moulding (10,000+).
Aluminium Bridge Tooling
Tooling in 3–5 weeks at AU$3,000–8,000 — a fraction of hardened-steel production tooling cost.
Production-Grade Polymers
Genuine engineering plastics — ABS, PC, PP, Nylon, PC-ABS — moulded to production specs, not prototype substitutes.
Validates Before Scale
Prove your market with 1,000 retail-ready parts before committing AU$30,000+ to hardened production tooling.
Same Polymer, Same Process
Unlike vacuum casting or 3D printing, low-volume injection uses the exact polymer and process you'll scale to — no surprises later.
Our Workflow
How a low-volume injection programme runs
Quote with target volume
Tell us your part design, polymer and how many you need. We'll quote aluminium tooling + per-part price together.
DFM and aluminium tooling
Standard DFM review then a single- or multi-cavity aluminium tool cut in 3–5 weeks.
T1 sample, sign off, run
First-shot parts inspected and signed off by you. Then production runs in batches sized to your release schedule.
Finish, pack, dispatch
Pad printing, hot-stamp, assembly, kitting and freight handled to your spec — direct-ship or to your warehouse.
What we deliver
Real production parts, without production-scale tooling commitment
Aluminium tooling · Production polymers · Same process you'll scale to
Low volume injection moulding hits the precise sweet spot between prototyping and mass production. You get real injection-moulded parts in the exact polymer, with the exact surface finish and exact mechanical properties you'll have at 100,000 units — but with tooling costs and lead times that make sense at launch volumes. It's the most effective way to validate a product in market before committing to full production tooling.
- Aluminium bridge tooling cut in 3–5 weeks from AU$3,000
- Genuine production polymers — ABS, PP, PC, Nylon, PC-ABS, ASA
- T1 sampling and dimensional approval before any production run
- Pad printing, hot-stamp, in-mould labelling and assembly available
- Same part dimensions and finish as future steel-tool production
- Designed for clean migration to hardened tooling once volume justifies it
Industries we serve
Where low-volume injection wins
Anywhere you need real moulded parts in production quantities of 100–10,000 — without committing to full production tooling.
Product Launches
Validate market demand with 500–5,000 launch units before committing to hardened steel production tooling.
Niche Consumer Brands
Direct-to-consumer brands and Kickstarter graduates who need real moulded parts but don't yet need 100,000 of them.
Medical Device Trials
Clinical trial quantities of moulded device housings, fluid components and disposables — in production-equivalent polymers.
B2B & Industrial Spares
Replacement covers, knobs and brackets for installed industrial equipment — 50–500 parts per release.
Film & Limited-Edition
Limited-run prop manufacturing and special-edition consumer products in true injection-moulded plastic.
Bridge to Full Production
Run on aluminium tooling while hardened steel tooling is being cut — keep selling product, never break inventory.
Showcase
Recent low-volume programmes
Low-volume production run on aluminium tooling — ABS consumer product.
Aluminium bridge tool fresh off the CNC, ready for first-shot sampling.
Packaged consumer parts shipping direct to the brand's warehouse.
FAQ
Frequently asked questions
Ready to start your project?
Upload your file or send a quick brief — most quotes come back within 4 working hours, with parts dispatched Australia-wide from our Sydney workshops.