Injection Molding Costs: What an Enclosure Really Costs

The question I get asked in every initial consultation: How much does an injection molding tool cost? The honest answer: It depends. But there are clear benchmarks you can use for planning.

The Three Cost Blocks in Injection Molding

Injection molding costs consist of three parts, which you should always consider separately:

1. Tool costs (one-time) – The injection mold itself
2. Per-unit costs (per part) – Material, machine time, cycle time
3. Ancillary costs – Tool modifications, quality inspection, storage

Tool Costs: The Big Investment

The injection mold is the single largest cost item. The price depends on size, complexity, and tool lifespan:

• Small mold (up to 50 cm²): €3,000 – €8,000
• Medium mold (50–200 cm²): €8,000 – €25,000
• Large / complex mold: €25,000 – €80,000+

Tip: Aluminum tools cost 30–50% less than steel and are perfectly sufficient for 500–5,000 parts. For most hardware startups, this is the smartest way to start.

Per-Unit Costs: What Each Part Really Costs

The unit price in injection molding drops dramatically with higher volumes. For a typical enclosure (PA6-GF30, 50 g):

• 100 parts: €8 – €15/unit
• 1,000 parts: €2 – €5/unit
• 10,000 parts: €0.50 – €1.50 /unit

The reason: Tool costs are amortized across the production volume. At around 500–1,000 parts, injection molding becomes cheaper than 3D printing or CNC machining.

5 Factors That Drive the Price

1. Geometry complexity – Undercuts, angled planes, and complex core pulls
2. Surface quality – SPI-A1 (mirror finish) costs more than SPI-D2 (matte/textured)
3. Material – Engineering plastics (PA, PPSU) are more expensive than standard (PP, ABS)
4. Tolerances – The tighter the tolerance, the more expensive the tooling process
5. Tool location – China: 40–60% cheaper, but longer lead times and higher communication overhead

When Does Injection Molding Make Sense?

The rule of thumb: Injection molding pays off at 300–500 parts, when the parts are intended for series production. Below that, 3D printing or CNC milling are almost always more cost-effective.

The break-even point depends on part complexity. For simple enclosures, injection molding can already be cheaper at 200 parts. For complex geometries, it may take 1,000+.

Anton Steenken

B.Eng. · Hardware R&D Engineer · Founder of engineer your idea