Small Batch Casting from China: Can You Make It Economically Viable?
You need 50 custom castings. The Chinese foundry's MOQ is 500. Can you make it work? Yes — here's how small batch casting actually works, what it costs, and how to structure the order for success.
The Small Batch Reality Check
The MOQ (Minimum Order Quantity) dilemma: foundries have setup costs (pattern making, mold setup, heat treatment batch minimums) that are fixed regardless of order size. Below a certain quantity, the per-part cost makes the order unprofitable for the foundry — or unaffordable for you.
The solution isn't eliminating minimums — it's structuring orders intelligently.
Process Options by Order Size
| Pieces Needed | Best Process | Tooling Option | Typical Tooling Cost |
|---|---|---|---|
| 1–10 | Investment (lost wax) | Hand-formed wax patterns | $200–800 |
| 10–50 | Investment | Soft tooling (aluminum) | $800–3,000 |
| 50–200 | Investment or shell mold | Soft tooling | $1,500–5,000 |
| 200–500 | Shell mold or resin sand | Production tooling | $3,000–10,000 |
5 Strategies to Reduce Small Batch Costs
- Combine orders: Accumulate parts over 2–3 months into a single larger order — most foundries will run multiple part numbers in one heat if you ask
- Use existing patterns: Many Chinese foundries have standard patterns for common parts (flanges, brackets, pipe fittings). Using an existing pattern eliminates tooling cost entirely
- Accept longer lead times: Small batches run as part of a larger production schedule. Lead time: 8–14 weeks vs. 4–6 weeks for dedicated runs — this is free money on the table
- Soft tooling first: Use aluminum tooling for pilot runs, move to steel tooling when you have volume commitment
- Design for process: Ask the foundry what part design minimizes tooling complexity — a simple part costs far less to pattern
Realistic Per-Part Costs (Investment Casting, Small Batch)
| Part Size | 50 pcs MOQ | 200 pcs | 500 pcs |
|---|---|---|---|
| Small (≤100mm, <1kg) | $3–12/pc | $2–6/pc | $1.5–4/pc |
| Medium (100–250mm, 1–10kg) | $15–40/pc | $8–20/pc | $5–12/pc |
| Large (250–500mm, 10–50kg) | $60–150/pc | $30–80/pc | $20–50/pc |
Prices include soft tooling, material, casting, and basic finishing. CNC machining and special testing are additional. Shipping is typically $2–5/kg CIF by sea.
Frequently Asked Questions
What is the minimum order quantity for casting from China?
Sand casting: 5–20 pieces minimum. Investment casting with soft tooling: 5–20 pieces. Production tooling investment: 50–200 pieces. True MOQ zero doesn't exist — someone pays for the pattern/tooling.
What is soft tooling?
Aluminum or soft metal patterns instead of hardened steel dies. Cost: $500–3,000. Tolerances: ±0.3–0.5mm. Best for: prototypes, pilot runs, orders under 200 pieces. Tooling life: 200–500 shots.
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