A pilot batch (20-100 pieces) is worth it when you consider: a new geometry for >500 pieces/year, a tolerance-critical fit, a sensitive application (medical, food contact, safety), or switching from prototype material (PA12) to production material (PA 950 HD). Cost: a few hundred euros. Saving: potentially thousands.
Four scenarios where a pilot pays off
New geometry for series. You have a prototype, now you want series. Test 20-50 pieces in production material before you place a large order. Identifies orientation effects and tolerance stack-ups.
Critical fit. Your part must fit into an existing assembly. Test 5-20 pieces in real assembly conditions.
Regulated application. Medical devices or food contact demand validation batches. Document material, process parameters and measurement results.
Material switch. From PA12 (prototype) to PA 950 HD (series): confirm mechanical and visual properties meet your requirements.
What you measure in a pilot
Focus on what is critical for your application.
Mechanical – Tensile test of 3-5 pieces against datasheet value.
Visual – 20-100 pieces on surface quality, colour, texture.
Dimensional stability – Critical dimensions with CMM or gauge.
Assembly – Trial assembly into the real assembly.
Long-term – For UV- or moisture-sensitive applications: 4-12 weeks conditioning and re-measure.
Regulated – Follow specific validation protocols (e.g. ISO 13485 for medical). We help set up your test protocol.
When you can skip a pilot
Prototype orders (1-5 pieces) – The pilot is the order itself.
Repeat orders of a validated part – Our COA + sample check is enough.
Non-critical applications (cable management, non-loaded covers) – One sample suffices.
Large runs of complex parts – Do not skip the pilot. The investment almost always pays itself back in avoided reprints or production line adjustments.
Our engineers gladly advise on the optimal pilot level for your specific case.