Free tool · 2026-Q3 edition
Tooling cost by process
Typical tool costs and cost per part, calibrated against published Protolabs and Xometry tiers and offshore rate cards. Size, material, cavities and finish move these numbers a lot.
| # | Process | Tooling | Per part | Typical volume | Best for |
|---|---|---|---|---|---|
| 1 | 3D printing (SLS / MJF) | $0 – $0 | $5 – $60 | 1 – 500 | Prototypes and very small runs; no tool at all. |
| 2 | Sheet metal (laser + brake) | $0 – $5.0k | $8 – $120 | 1 – 10,000 | Brackets and enclosures; soft tooling only for high volume. |
| 3 | Urethane casting | $0.5k – $3.0k | $15 – $80 | 10 – 200 | Production-like plastic parts before committing to a mold. |
| 4 | Plastic extrusion | $1.0k – $8.0k | $0.20 – $5 / m | Continuous | Constant cross-section profiles, tubes and seals. |
| 5 | Aluminium injection mold | $1.5k – $38k | $0.50 – $8 | 500 – 10,000 | Bridge tooling and early production runs. |
| 6 | Thermoforming | $2.0k – $15k | $2 – $25 | 250 – 10,000 | Large, thin shells, trays and covers. |
| 7 | Steel injection mold | $6.0k – $150k | $0.20 – $5 | 10,000 – 1M+ | High-volume plastic parts with long tool life. |
| 8 | Die casting (aluminium / zinc) | $15k – $120k | $2 – $30 | 5,000 – 500,000 | Strong metal housings and heat sinks at volume. |
| 9 | Metal injection molding (MIM) | $20k – $100k | $1 – $15 | 10,000+ | Small, complex steel parts. |
Planning ranges, not quotes. See the manufacturing cost guide.