Low-Volume Production
From Prototype to Production — Without the Overhead

Protoproof’s low-volume manufacturing services bridge the gap between rapid prototyping and full-scale production.

We specialize in small batch manufacturing, short-run production, and custom packaging. This gives startups, engineers, and manufacturers the ability to test markets, validate designs, and scale production at the right pace — all with fast turnaround times and precision quality.

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Our Process

1. Production Planning – We evaluate your proven prototype and define a manufacturing plan aligned with final production requirements.

2. Material & Method Selection – Choose from metals, thermoset polymers, thermoplastics, etc. We match your project to the best methods: CNC machining, cast or injection molding, additive manufacturing, or a completely custom fabrication process, depending on functional and financial constraints.

3. Small Batch Production – Produce short runs or limited quantities with full production-level tolerances and quality control.

4. Scale-Up Support – Transition seamlessly to larger manufacturing runs with our vendor partnerships and in-house process expertise.

Production Planning

Adding in proper interferences, factoring in the coefficient of linear thermal expansion, ordering a co-polymer instead of a homopolymer, and material shrinkage after cooling, are some of the many variables we factor when preparing a prototype for production.

Case Study - Vaucluse Gear: Production planning was critical in the transition from 3D printed 95A TPU to 20% glass-filled HDPE. Understanding tolerance translation when factoring both a process and material change was imperative toward a final, functional, injection-molded product. In this case, we had to increase the interference of the mating feature to 0.004".

Different versions of the vaucluse gear backpack spacer that all were injection molded with different materials including HDPE, LDPE, TPV, TPE

Material & Method Selection
Prototype-to-Production

There are 8 factors to consider when selecting a material for a mass production process (i.e. cast molding, injection molding, etc.)

Example: If designing an automotive exterior clip, you’d prioritize: UV resistance, flame rating, fatigue resistance, and dimensional stability. For a medical device handle, you’d prioritize: biocompatibility, sterilization resistance, ergonomics, and surface finish.

1. Mechanical Properties:

Strength & Stiffness: Does the part need to withstand high loads or stress? (e.g., Nylon, PEEK for high-performance).
Impact Resistance: For parts subject to drops, shocks, or vibration (e.g., ABS, Polycarbonate).
Flexibility/Elasticity: If parts need to bend without breaking (e.g., TPU, TPE, LDPE).

2. Thermal Properties

Operating Temperature Range: What temps will it see in use (continuous + peak)?
Heat Deflection Temperature (HDT): At what temperature does the material deform under load?
Thermal Expansion: Important for parts that fit tightly with metals or other materials.

3. Environmental Resistance

UV Resistance: Outdoor or sun-exposed applications (e.g., ASA, UV-stabilized PP).
Moisture Resistance / Hydrolytic Stability: Especially for humid or wet environments.
Chemical Resistance: Oils, fuels, solvents, cleaners. (e.g., Acetal, PP, PVDF).
Flame Resistance: Compliance with UL 94 flammability standards, if required.

4. Regulatory & Safety Requirements

Biocompatibility (ISO 10993, USP Class VI): For medical or skin-contact applications.
Food-Grade / FDA Compliance: For kitchen, packaging, or food-contact parts.
Electrical Properties: Conductive, insulative, or static-dissipative requirements.
5. Aesthetic & Surface Requirements
Color & Finish: Can it be pigmented or textured?
Transparency: Optical clarity for lenses or housings (e.g., PC, Acrylic).
Surface Durability: Scratch resistance, gloss retention, paintability.

A chart comparing different plastic molding techniques across different quantity and/or part utility needs.

6. Dimensional Precision & Tolerances

Shrinkage Rate: Critical for injection molding — varies by polymer (PP vs ABS vs Nylon).
Creep Resistance: Will the part deform slowly under constant load?
Tolerance Holding: Needed for tight fits or assemblies.

7. Processing & Cost Factors.

Moldability: Ease of flow, cycle time, tool wear (e.g., glass-filled materials are abrasive).
Availability: Commodity vs specialty resin.
Cost per Pound: Balance between material performance and part economics.
Recyclability / Sustainability: Increasingly important for brand and compliance.

8. Lifecycle & End Use

Expected Service Life: Will the part need to last months, years, or decades?
Recycling/Disposal Needs: Regulatory or sustainability considerations.
Consistency: Batch-to-batch repeatability for critical applications.

Case Study: TESBROS Cybertruck Side Mirror Delete

We provided a part for a client that sells aftermarket Tesla products. For a show, they wanted a custom bracket with a plate mount that would replace the side mirror for car meetups to have a Tesla Cybertruck - without the side mirrors.

The most critical constraints we had to control were impact resistance, wide temperature ranges (-20F to 140F), UV resistance, and thermal expansion between the polymer-based bracket and the 15Ga stainless steel. It also needed to have a specific, brushed surface finish on the metal. We needed to be able to provide several batches of 50 units as they were deployed in "limited stock" waves to better engage their audience and to help establish urgency to purchase a limited run product.

Small Batch Production

We ensure every small batch is aligned with final manufacturing requirements, including:

✅ Tolerances and Precision – Parts built to the same standards as mass production.
✅ Material Specifications – Plastics, metals, and composites matched to your application.
✅ Surface Finishes & Aesthetics – Ready-for-market quality.
✅ Assembly Methods – Parts delivered as standalone components or pre-assembled units.

Case Study - Vaucluse Gear: Prior to injection molding 20,000 frames, Protoproof provided 220 assembled sets of the first-generation outdoor backpack ventilation frame.

We used a variety of custom-tailored processes to weld together 3D printed 95A TPU parts and utilize PETG 3D printed spacers between the 95A TPU frames to allow for both rigidity and flexibility.

Vaucluse Gear would order 30 units at a time, and this allowed for steady, organic market penetration as they were not immediately burdened with heavy tooling costs.

Low volume production run of large format 3D printed parts.

While their price-per-unit was higher, the goal was to dial in the correct audience for running digital marketing campaigns and optimize the audience retargeting.

This allowed Vaucluse Gear to take the next steps confidently, knowing that their advertising reach would be optimized prior to injection molding.

This is a loaded injection molding die plate. This is Vaucluse Gear's die plate.

Scale-Up Support

Our scale-up support services help you transition seamlessly from small batch production to low-volume or full-scale manufacturing. We ensure that your proven prototype and pilot runs are fully synchronized with supply chain, materials, and manufacturing processes, reducing risk and speeding time-to-market.

✅ Design for Manufacturing (DFM) Refinement – Ensuring parts are optimized for mass production.
✅ Vendor Partnerships – Guidance on tooling, injection molding, or casting suppliers. both domestic and international.
✅ Material Scale-Up – Selecting resins, metals, or composites available at commercial volumes.
✅ Quality & Traceability – Implementing inspection, certification, and process documentation.