3D printing for SMEs: prototypes & small series

Lisa Ernst · 22.11.2025 · Technology · 8 min

Perhaps you know this from your own company: someone has a clever idea for a small jig, a new housing, or a tool for assembly – everyone is enthusiastic, you get a quote, and then the idea disappears into a drawer for months. Tooling is too expensive, milled parts take weeks, and internally no one has time for “such a small project”.

You are not alone in this. SMEs make up over 99% of companies in Switzerland and provide around two-thirds of jobs – at the same time, many businesses struggle with scarce resources and high time pressure ( kmu.admin.ch). ). It is precisely in this environment that 3D printing can close a gap: prototypes, jigs, and small series become a reality within days instead of weeks, without you having to commit to expensive tooling immediately.

We at 33d.ch work daily with Swiss SMEs who are facing exactly this decision: is 3D printing really worth it for our part? In this article, we show you in a practical way what 3D printing is suitable for in the SME environment, how a typical project proceeds, and which pitfalls you can avoid – based on what works in our daily operations (and what we’ve learned ourselves along the way).

Quelle: Own illustration

Why 3D printing is so well-suited for SMEs

3D printing doesn't replace every milling machine or injection molding. But it plays to its strengths precisely where SMEs often fall between the cracks:

• Small quantities: 1–200 parts, often in several iterations.
• Uncertain design: Geometry may still change, feedback from the field is welcome.
• Short time-to-market: Weeks of tooling lead times don't fit the project plan.
• Limited budget: Investments in tooling should only come when the product has “taken off”.

For exactly these situations, we use 3D printing as a “bridge” between idea and series production: parts can be tested, adapted, and used in small series without you being locked in prematurely.

Comparison: traditional way vs. 3D printing

Technologies & materials – only what you need to know

There are many abbreviations and processes on the market. For you as an SME, the most important thing is: which process suits your application and budget? We will focus here on the technologies that we recommend most frequently for prototypes and small series.

FDM: the “Swiss Army knife” of printing

In Fused Deposition Modeling (FDM), a plastic filament is melted and built up layer by layer according to a CAD model. The technology is widespread, well understood, and can work with a wide range of materials – from simple PLA prototypes to technical plastics ( Protolabs Network; Xometry Pro).

We mainly use FDM when

• you need a functional prototype quickly and cost-effectively,
• the appearance can be “good, but not high-gloss”,
• you are looking for jigs, holders, or auxiliary tools for production.

SLA, SLS & MJF: when finer or more robust is needed

SLA (Stereolithography) works with liquid resins and a laser. Advantage: very fine details and smooth surfaces, ideal for design prototypes or components with high visual requirements ( (Formlabs).

SLS (Selective Laser Sintering) and MJF (Multi Jet Fusion) process plastic powders (typically PA12). The parts are robust, dimensionally stable, and very well suited for functional end-use parts and small series ( (Formlabs; ABCorp).

Material overview for everyday SME use

In practice, a few standard materials suffice for many projects. Simply put:

If you want to delve deeper into the topic of materials, a thorough video on material selection is also worthwhile. A good English-language example is this overview video on PLA, PETG, ABS, TPU & Co.: „When to use PLA, PETG, ABS, TPU, Polycarbonate, Nylon etc.“

Quelle: 3d-druck-berlin.com

From CAD model to the first sample part: This is exactly where 3D printing shortens the time span from idea to real-world component testing in everyday SME operations.

How a 3D printing project with an SME typically proceeds

Many projects at 33d.ch follow a similar pattern. The general process helps you clarify internally what you can already provide and where you still need support.

1. Inquiry: Describe the problem, not just the geometry

It's easiest when you don't just send us a STEP or STL file, but briefly explain what the part is supposed to do in everyday use:

• Where will it be used (machine, lab, outdoor area)?
• What temperatures, chemicals, or forces will it be exposed to?
• How many parts do you need in the next 3–12 months?
• Is the geometry already fixed, or do you expect changes?

Based on this information, we will decide with you whether FDM with a robust filament is sufficient or whether an industrial process like MJF/SLS with PA12 makes more sense ( (ABCorp; BCN3D Technologies).

2. Data check & fine-tuning of the design

In the next step, we check the data. Typical points we repeatedly see:

• Walls too thin (e.g., < 1 mm in stressed areas).
• Screw holes without clearance – with 3D printing, you often need a bit more room than in a milling drawing.
• Sharp internal edges that make the print more susceptible.

Honestly: we also made these mistakes ourselves at the beginning. Only after several projects do you learn where it’s better to add 0.2 mm or incorporate a chamfer. We now alleviate this learning curve for our customers by actively providing feedback on the design.

3. Choice of technology and material

Together, we decide which process and which material makes the most sense. A typical mix from our daily operations:

• PLA / PETG (FDM): for initial functional prototypes, simple housings, test gauges in an office environment ( (burg-halle.de).
• Technical FDM materials: e.g., glass fiber reinforced filaments for rigid jigs in production ( (BCN3D Technologies).
• PA12 (MJF/SLS): for robust small series, clips, snap-hooks, and housings that need to last a long time in the field ( (ABCorp).

4. Sample parts & iterations

Once the key parameters are clear, we usually print 1–5 sample parts first. Online service providers like i.materialise or Protolabs indicate production times of a few working days for many plastics ( (i.materialise.com; Protolabs Network). ). In our practice, this often means:

• Week 1: First sample, short test on the machine or in the lab.
• Week 2: Adjust geometry (e.g., grip, radii, tolerances), second iteration.
• Week 3: Approval for small series.

The actual times naturally depend on material, size, and workload – but instead of "we're waiting for the tooling", you ideally have a part that works in everyday use after two or three weeks.

5. Small series & repeat orders

If the sample is convincing, we scale up to the desired quantity. Industrial examples show that 3D printing can be economically used for small series of tens to several hundred parts ( (BCN3D Technologies; ABCorp).

In practice, we agree on fixed batch sizes with many SMEs (e.g., 50, 100, or 250 units) and define how quickly reorders can be placed. The CAD data remain digital – if it becomes apparent in the field that a detail is not yet optimal, it is adjusted, and the next batch will already come with an update.

Quelle: 3d-druck-berlin.com

From a problem in production through CAD design to the finished part in a small series – 3D printing significantly shortens this path.

Practical examples of use

So that it's not just theoretical, here are two anonymized examples from our daily work with Swiss SMEs.

Case study 1: Assembly jig for a mechanical engineering company (Central Switzerland)

A medium-sized mechanical engineering company came to us with a problem: in assembly, sensitive aluminum profiles were always positioned "by feel". This led to misalignment, rework, and discussions between shift teams.

• Initial situation: 12 workstations, oily environment, occasional impacts. Previous solution: milled jigs with around four weeks delivery time and high individual costs.
• Our solution: We first designed and printed an FDM jig made of PETG. After two assembly tests, we strengthened the support surfaces, ergonomically adjusted the handles, and incorporated press-in nuts. The second iteration was stable enough for continuous use, so all 12 jigs were manufactured within a few days.
• Result: Significantly less rework, reproducible assembly times, and noticeably less stress on the line. The company incurred no tooling costs, and changes during ongoing operations remain possible.

According to various manufacturers, such 3D-printed jigs and auxiliary tools can reduce lead times by 40–90% and costs by 70–90% – depending on complexity and the basis for comparison ( (UltiMaker; Zmorph S.A.; BCN3D Technologies).

Case study 2: Small series for a sensor housing (Greater Zurich Area)

A technology start-up wanted to test an IoT sensor housing in several pilot projects. The design was not yet final, and customer feedback was to be incorporated directly into the next version.

• Initial situation: Need for 80–150 housings, robust mechanics, clean appearance, limited budget – an injection mold would have been too early.
• Our solution: First, we produced SLA samples with a very smooth surface for design and haptic testing. Then, for the small series, we switched to an MJF-PA12 material to obtain robust end-use parts, as described in many industrial applications ( (ABCorp). ). The first series of 100 housings was in use after a few weeks.
• Result: The start-up was able to collect real field data with a professional-looking product, without committing to an injection mold in the first year. Several details were adjusted between pilot series (cable entry, snap-fits) without incurring additional tooling costs.

Typical pitfalls – and how we avoid them today

Many 3D printing errors are only visible when the part is in your hand. A few classics from our workshop:

Many of these points can be clarified in a brief technical discussion. At 33d.ch, we've made it a habit to question critical details one more time before starting a larger series – this saves everyone involved headaches.

Checklist: Get the most out of your 3D printing project

When you start a new project, you can use these points as a short checklist:

• ✅ Problem clear? Don't just describe the part, but its application and requirements.
• ✅ Target quantity defined? Estimate rough quantities for the next 3–12 months.
• ✅ Environment known? Temperature, chemicals, weather, mechanical loads.
• ✅ Critical contact surfaces marked? E.g., sealing surfaces, mating fits, visible areas.
• ✅ Iterations planned? Realistically expect 1–3 rounds, instead of "perfect right away".
• ✅ Data clean? STEP/STL without gaps, wall thicknesses checked, threads/press-in nuts considered.
• ✅ Internal communication clarified? Who decides on approvals, who tests the part in everyday use?

Key takeaways:

• 3D printing is not an end in itself for SMEs, but a tool to implement prototypes, jigs, and small series faster and more flexibly.
• The biggest levers are in time and risk: instead of investing in tooling early, designs can be iteratively improved.
• With the right processes and materials – from FDM with PLA/PETG to MJF/SLS with PA12 – near-series parts can be produced.
• Many typical problems (tolerances, clips, warping) are solvable if addressed early and leverage practical experience.
• A good 3D printing partner understands not only machines but also your process as an SME – and thinks with you in iterations rather than one-off projects.

Fits well with (internal link ideas)

• Understanding 3D printing tolerances
• Storing filament correctly
• Design rules for 3D-printed jigs
• Comparison of 3D printing technologies for SMEs
• Cost calculation for 3D printing small series