With SLS you spread the fixed costs per build (heat-up, cool-down, order overhead) across more parts. Larger runs share the same oven cycle. Bonus: for large runs we often recommend PA 950 HD (35% lower material cost) and optimise the build nesting. In practice: 20-40% lower per-piece cost from 10 to 500 pieces.
Where the scale effects sit
An SLS build is a time block of 24-40 hours (heat-up + print + cool-down). Whether it processes one part or three hundred, the oven heats once and cools once. Fuller build = more parts share the fixed cost.
Order handling, quality control, packaging and shipping are almost identical for 10 or 500 pieces. Spread out, per-piece overhead drops. And the fuller the build, the more efficient the powder management.
What changes above 100-500 pieces
At larger runs we can add optimisations. We actively nest your parts together (sometimes dedicated builds per customer order). We more often recommend PA 950 HD because 80% powder reuse only pays off at sufficient volume. We plan builds on our largest machines (P500 dual-laser, 500x330x400 mm).
For recurring orders we lock in pricing. You do not have to re-quote each time and profit from a fixed ratio.
Up to what run size SLS stays competitive
For most polymer parts SLS remains attractive up to around 5,000-10,000 pieces per year. Above that, injection moulding after the mould investment is often cheaper per piece in stable PA12 designs.
We say that honestly. Simple geometry and >=10,000/year stable? Then we recommend a mould business case. We may still print the first 6-12 months of bridge production while you build the mould.