Small Batch production

Smart production in small batches.

There are many reasons to produce your product in small batches. Most contract manufacturers are only interested in large quantities. Pilotfish helps companies bring products to market without requiring large production volumes from the start.

Why produce in small batches?

Larger batch sizes usually mean a lower product price, as NRE, tool and overhead costs are divided across more products, with lower raw material prices and higher yield rates.

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But TCO (Total Cost of Ownership) and TTM (Time to Market) matter too, making small-batch production the right choice in many situations.

Lower Upfront Investment

Product Flexibility

Faster Time to Market

Reduced Inventory Risk

Cash

Large batches reduce the unit price, but require more upfront investment in components and stock. Small batches help preserve cash while testing the market and developing sales channels.

Speed

When time to market matters, there may be no time to build a complete production and assembly line. Small batches help you move from product to market faster.

Time-sensitive

Market demands and technologies can change quickly. Small-batch production gives you the flexibility to improve and adapt the product between production runs.

Niche specialized market

Specialized markets may require lower volumes without compromising on quality. Small batches make high-quality production viable even when you simply don’t need large quantities.

How we make small-batch production work?

Product design

It is important to have realistic forecasts when Pilotfish designs the product. Many design decisions are directly related to batch size and product cost.

Scalable & modular design

Design the product to be ready for future upgrades while reducing features in the first version.

Low-MOQ components

Select components and raw materials with low MOQs and, where possible, materials that are available from stock.

Generic components & second sources

Use generic components with a second source to reduce supply-chain risk.

Simple housing assembly

Design housings with screws rather than relying on glue or snap-fit solutions.

Tools

For small batches, tooling should match the expected production volume rather than being over-engineered for volumes you may not need.

Rapid & soft tooling

Use rapid or soft tooling to reduce upfront investment and shorten lead times for small production volumes.

Match tool life to volume

Choose tool life based on expected volume to reduce investment without compromising part quality.

Multi-cavity tools

Combine multiple parts in one tool to reduce tooling costs and simplify production.

Avoid unnecessary tooling complexity

Avoid complex processes like 2K moulding and overmoulding where simpler tooling can meet production needs.

Assembly

For small-batch production, assembly should stay flexible. Manual and jig-assisted processes help reduce upfront investment while keeping production ready to scale as volumes grow.

Manual & jig-assisted assembly

Use manual and jig-assisted assembly to stay flexible and reduce upfront investment.

Avoid early automation

Avoid custom automation until production volumes justify the additional investment.

Plan partial deliveries

Purchase components in larger quantities while assembling and delivering products in smaller batches.

Balance stock & batch costs

Balance build-to-stock and build-to-order to reduce inventory and per-batch costs.

Ready to produce in small batches?

Let’s discuss your product and find the right way to bring it to market.