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 fixture, a new housing, or an assembly aid – 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 nobody 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 the jobs – at the same time, many businesses struggle with tight resources and high time pressure ( kmu.admin.ch). It is precisely in this environment that 3D printing can bridge a gap: prototypes, fixtures, and small series become a reality within days instead of weeks, without you having to commit to expensive tooling immediately.

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

Source: Own representation

Why 3D printing is a good fit for SMEs

3D printing does not replace every milling machine or injection molding machine. But it plays to its strengths precisely where SMEs often end up between a rock and a hard place:

• Small quantities: 1–200 parts, often in multiple iterations.
• Uncertain design: Geometry may still change, feedback from the field is desired.
• Short time-to-market: Tooling lead times of weeks do not fit the project plan.
• Limited budget: Investments in tooling should only come when the product has "taken off."

It is precisely for these situations that we use 3D printing as a "bridge" between idea and series tooling: parts can be tested, adapted, and used in small series without early commitment.

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 widely used, well understood, and can work with a wide range of materials – from simple PLA prototypes to technical plastics (Protolabs Network; Xometry Pro).

We use FDM primarily when

• you need a functional prototype quickly and cost-effectively,
• the appearance can be "good, but not high-gloss",
• you are looking for fixtures, holders, or assembly aids for production.

SLA, SLS & MJF: when it needs to be finer or more robust

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 Multi Jet Fusion (MJF) 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 are sufficient for many projects. Simply put:

If you want to delve deeper into the topic of materials, a well-founded 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.“

Source: 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 component testing in everyday SME life.

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 deliver and where you still need support.

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

It becomes easiest when you not only send us a STEP or STL file, but briefly explain what the part should achieve in everyday use:

• Where will it be used (machine, laboratory, outdoors)?
• What temperatures, chemicals, or forces will it be subjected 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 if an industrial process like MJF/SLS with PA12 would be more sensible (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 – in 3D printing, you often need a bit more space than in a milling drawing.
• Sharp inner edges that make the print more fragile.

To be honest: we experienced this ourselves at the beginning. Only after several projects do you learn where it is better to add 0.2 mm or incorporate a chamfer. We now spare our customers this learning curve by actively providing feedback on the design.

3. Technology and material selection

Together, we determine which process and which material makes the most sense. A typical mix from our everyday work:

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

4. Sample parts & iterations

Once the key data is 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., handle, 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 practice 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 dozens to several hundred parts (BCN3D Technologies; ABCorp).

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

Source: 3d-druck-berlin.com

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

Practical application examples

So that it doesn't remain purely theoretical, here are two anonymized examples from our everyday work with Swiss SMEs.

Case study 1: Assembly fixture for a mechanical engineer (Central Switzerland)

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

• Starting situation: 12 workstations, oily environment, occasional bumps. Previous solution: milled fixtures with a lead time of around four weeks and high individual costs.
• Our solution: We first designed and printed an FDM fixture made of PETG. After two assembly tests, we reinforced the support surfaces, ergonomically adjusted the grips, and incorporated press-in nuts. The second iteration was stable enough for continuous use, so all 12 fixtures were produced 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 fixtures and aids can reduce throughput times by 40–90% and costs by 70–90% – depending on complexity and basis of 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.

• Starting situation: Demand of 80–150 housings, robust mechanics, clean appearance, limited budget – an injection molding tool would have been too early.
• Our solution: First, we produced SLA samples with a very smooth surface for design and haptic tests. Then, for the small series, we switched to an MJF-PA12 material to obtain robust end 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 molding tool in the first year. Between the pilot series, several details were adjusted (cable entry, snap hooks) without incurring additional tooling costs.

Typical pitfalls – and how we avoid them today

Many errors in 3D printing 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 have made it a habit to question critical details one more time before starting a larger series – this saves nerves for everyone involved.

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

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

• ✅ Problem clear? Describe not just 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 surfaces marked? E.g., sealing surfaces, fits, visible areas.
• ✅ Iterations planned? Realistically expect 1–3 cycles, instead of "perfect immediately."
• ✅ 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, fixtures, and small series faster and more flexibly.
• The biggest leverage lies in time and risk: instead of investing in tooling early on, 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) can be solved if they are addressed early and experience from practice is utilized.
• A good 3D printing partner not only understands machines but also your process as an SME – and thinks with you in iterations rather than one-off projects.