What Is Small Batch Production and Why Is It So Demanding?
Small batch production refers to the manufacture of components in typical quantities of 5 to 500 pieces. Unlike mass production, where all fixed costs are spread across thousands of parts, in small batches setup times, programming and quality assurance must be allocated to a significantly smaller number of units.
This makes the choice of the right manufacturing partner particularly critical: a partner primarily set up for large series will often view small batches as unattractive — with correspondingly long lead times and high prices.
Understanding the Cost Structure of Small Batches
Fixed Costs vs. Variable Costs
In small batches, fixed costs often make up 60–80% of the unit price:
- CNC programming: A complex 5-axis program costs the same whether you produce 10 or 10,000 parts
- Setup time: Setting up the machine, presetting tools, establishing work offsets — this takes 20–90 minutes per setup
- First article inspection: The first part is completely measured and documented
How a Good Partner Reduces Fixed Costs
Experienced small batch manufacturers have developed strategies to reduce these fixed costs drastically. At Strobel Industry, for example, we use modular zero-point clamping systems that reduce setup time by up to 70%. Our extensive CAM libraries allow standard geometries to be programmed in minutes rather than hours. More on this in our article about Cost Factors in Machining.
Technology for Economical Small Batches
Modern CAD/CAM Systems
Powerful CAM software with feature recognition and adaptive strategies significantly reduces programming time. Recurring geometries such as pockets, hole patterns and contours are generated from templates.
Flexible Clamping Technology
Modular clamping systems such as vices with interchangeable jaws, vacuum clamping or zero-point systems enable quick changeovers between different components — without time-consuming alignment.
High-Speed Machining
Modern machining centres with spindle speeds up to 24,000 rpm and dynamic feed rates significantly shorten cycle times. This is particularly noticeable with aluminium small batches. Which aluminium alloy is the right one is explained in our Aluminium Alloys Comparison.
Checklist: Finding the Right Small Batch Partner
Technical Competence
- Experience with small lot sizes (not just large series)
- Modern machine fleet with quick setup capabilities
- In-house CAM programming (no outsourcing of programming)
- Material competence for your materials
Organisational Strengths
- Fast response times on enquiries (ideally 24h)
- Flexible capacity planning (short-notice orders possible)
- Transparent pricing with traceable calculations
- Prototype capability — from one-off parts to small batches without detours
Quality and Reliability
- Measurement reports and documentation as standard
- Schedule reliability with binding delivery times
- Proactive communication in case of problems or delays
Typical Use Cases for Small Batches
Small batch production is the preferred production form in many industries:
- Mechanical engineering: Special parts for custom machines (10–100 pieces)
- Medical technology: Instruments and implants in small batches
- Motorsport: Performance components in micro-batches
- Prototype phase: Pre-series for validation before mass production
- Spare parts: Re-manufacturing of no-longer-available components
Frequently Asked Questions (FAQ)
From what quantity is a small batch?
In CNC manufacturing, quantities of 5 to 500 parts are considered small batches. Below that is one-off or prototype production; above that, medium-series production begins.
Are small batches more expensive than large series?
The unit price is higher because fixed costs (setup, programming) are spread across fewer parts. However, a specialised partner can significantly minimise the difference — often to just 20–30% above large-series unit prices.
How long does a CNC small batch take?
Typical lead times for small batches are 2 to 4 weeks. For simpler parts or with an existing program, even faster.
Conclusion: Flexibility and Efficiency Decide
The right partner for small batch production combines technical competence with organisational flexibility. They understand that small batches require different processes than mass production — and have optimised their workflows accordingly.
Planning a small batch? Send us your documents — we'll prepare a transparent quotation with a binding delivery time.