3D Printing One-Step Process: Guide to Fast, Cost-Effective Manufacturing

Gone are the days of complex, multi-step manufacturing that takes weeks to turn a design into a physical part. The 3D printing one-step process has changed the game: it transforms a digital 3D (CAD) model directly into a tangible prototype or end-use part—no extra tooling, no assembly lines, no long waits. Whether you’re a small business making prototypes or a manufacturer scaling production, this guide will show you how to leverage the one-step process to save time, cut costs, and avoid common pitfalls.

1. What Is the 3D Printing One-Step Process?

The 3D printing one-step process is exactly what it sounds like: a single manufacturing stage that turns a digital design into a physical object. Unlike traditional methods (like injection molding, which requires creating molds first, or machining, which involves cutting and shaping material), 3D printing builds parts layer by layer directly from the CAD file.

How It Works in Simple Terms

1. Design: You create or download a 3D CAD model (using software like Fusion 360 or Tinkercad).
2. Prepare: You slice the model into thin layers (using software like Cura) and send the file to your 3D printer.
3. Print: The printer deposits or fuses material (like filament or powder) layer by layer to build the part.
4. Finish (Optional): For some projects, you might add simple post-processing (like sanding), but this is often minimal—unlike traditional manufacturing’s multiple finishing steps.

The key here is that there’s no “middle step” (like mold-making). This is why the one-step process is so fast and cost-effective, especially for small batches or custom parts.

2. Why Choose the One-Step Process? 4 Key Benefits

The 3D printing one-step process solves major pain points of traditional manufacturing. Here’s how it helps users:

1. Faster Turnaround Times

Traditional manufacturing can take 2–4 weeks to make a prototype (e.g., creating a mold for injection molding takes 1–2 weeks alone). With the one-step process, you can print a part in hours to days.

Example: A startup in Berlin needed a prototype for a new phone case. Using FDM (a one-step technology), they uploaded their CAD model at 9 AM and had a physical prototype by 3 PM the same day. With traditional machining, this would have taken 5–7 days.

2. Lower Costs for Small Batches

Traditional methods have high upfront costs (e.g., a mold for injection molding can cost \(1,000–\)10,000). The one-step process eliminates these costs—you only pay for the material and print time.

3. Design Freedom

The one-step process lets you print complex designs (like hollow parts, internal structures, or organic shapes) that are impossible or expensive with traditional methods. You don’t have to “simplify” your design to fit a mold or machining tool.

4. Less Waste

Traditional manufacturing cuts or grinds material, leading to 30–50% waste. The one-step process uses only the material needed to build the part, reducing waste to 5–10% (and many materials are recyclable).

3. Top 3 One-Step 3D Printing Technologies (Compared)

Not all one-step 3D printing technologies are the same. The best choice depends on your project (e.g., prototype vs. end-use part, budget, material needs). Below is a breakdown of the three most popular, cost-effective options—based on data from Xometry, a leading 3D printing service.

Key Takeaway: For most beginners or budget-focused projects, FDM is the best one-step option. For durable, high-volume parts, MJF offers the best value (note the big cost drop when ordering 20 units!).

4. How to Optimize the One-Step Process for Lower Costs

The one-step process is already affordable, but you can save even more by tweaking your design and settings. Below are the most impactful ways to cut costs—based on Xometry’s cost factors.

1. Adjust Part Volume

The cost of one-step 3D printing is directly tied to the volume of the part (more material = higher cost). To reduce volume without changing the part’s function:

• Make the part more compact (e.g., shrink empty spaces that don’t affect strength).
• Avoid over-sizing (print only the size you need—no extra material).

Example: A furniture designer was printing a 3D-printed chair leg that was 15cm tall. By reducing the height to 12cm (still strong enough) and making the base narrower, they cut material use by 25%—lowering the cost from €18 to €13.50 per leg.

2. Optimize Wall Thickness

Wall thickness affects both cost and strength. Thicker walls use more material (higher cost), but too-thin walls break easily. Follow these guidelines for one-step printing:

• FDM: Minimum wall thickness = 1.2mm (thicker if the part needs strength).
• SLS: Minimum wall thickness = 0.7mm.

Pro Tip: Use thinner walls for non-load-bearing parts (e.g., a decorative cup) and thicker walls for load-bearing parts (e.g., a shelf bracket). This balances cost and durability.

3. Hollow Out Parts (When Possible)

Hollowing out parts is a great way to save material in the one-step process. Less material = lower cost and lighter parts. Just remember:

• Leave small holes in hollow parts to let air escape during printing (prevents warping).
• Don’t hollow critical areas (e.g., the base of a chair leg—keep it solid for strength).

Example: A toy company was printing plastic action figures with solid bodies. By hollowing the torso (leaving a 2mm wall), they reduced material use by 40%—saving €5 per figure when printing 100 units.

4. Minimize Support Structures

Support structures are extra material the printer uses to hold up overhanging parts (e.g., a “roof” on a part). They add cost (more material) and time (you have to remove them after printing). To reduce supports:

• Design parts with self-supporting angles (45 degrees or more—no supports needed for overhangs at this angle).
• Choose technologies that don’t need supports (e.g., SLS or MJF—they use powder as support).

Cost Impact: For an FDM part with lots of overhangs, supports can add 10–20% to the material cost. By adjusting the design to 45-degree angles, you eliminate this extra cost.

5. Real-World Use Cases of the One-Step Process

The one-step process isn’t just for prototypes—it’s used in industries from healthcare to automotive. Here are two examples of how it solves real problems:

Case 1: Medical Prototyping (FDM One-Step Process)

A small clinic in Madrid needed a prototype of a custom knee brace for a patient. With traditional manufacturing, this would have required:

1. Creating a mold (2 weeks, €1,500).
2. Casting the brace (1 week, €300).
3. Finishing (3 days, €200).

Total: 3.5 weeks, €2,000.

Using the FDM one-step process:

1. The clinic scanned the patient’s knee and created a CAD model (1 day).
2. They printed the prototype (8 hours, €50 in PLA material).
3. They sanded the edges (1 hour, no extra cost).

Total: 1.5 days, €50.

The clinic tested the prototype, made small tweaks to the CAD model, and printed the final brace—all in under a week.

Case 2: Small-Batch Production (MJF One-Step Process)

A startup in Amsterdam makes custom phone grips. They needed to produce 50 grips for a launch. With injection molding (traditional):

1. Mold cost: €3,000.
2. Production time: 2 weeks.
3. Unit cost: €2 (total: €100 for 50 units + €3,000 mold = €3,100).

Using the MJF one-step process:

1. No mold cost.
2. Production time: 3 days.
3. Unit cost: €15.96 (PA 12 material, total: €798 for 50 units).

The startup saved €2,302 and got their grips to market 11 days faster. For small batches, the one-step process is unbeatable.

Yigu Technology’s View on the 3D Printing One-Step Process

At Yigu Technology, we see the one-step 3D printing process as a catalyst for accessible manufacturing. It levels the playing field—small businesses and startups no longer need big budgets for tooling to bring ideas to life. We recommend FDM for beginners (low cost, easy to use) and MJF for businesses scaling small batches (fast, high accuracy). Our team also helps clients optimize designs: we recently worked with a furniture brand to hollow their chair parts, cutting material costs by 35% while keeping strength. The one-step process isn’t just fast—it’s smart, and we’re investing in tools to make it even more affordable for everyone.

FAQ: Your Questions About the 3D Printing One-Step Process Answered

1. Can the one-step process be used for large-scale production (1,000+ units)?

The one-step process works best for small-to-medium batches (1–500 units). For 1,000+ units, traditional methods like injection molding may be cheaper (once you cover the mold cost). That said, technologies like MJF are getting faster—some manufacturers use it for 1,000-unit batches if the part is complex (e.g., custom electronics).

2. Do I need expensive software to use the one-step process?

No! There are free, user-friendly tools for every step:

• CAD design: Tinkercad (free for beginners), Fusion 360 (free for startups/students).
• Slicing: Cura (free, works with most printers).
• You can even download pre-made CAD models from sites like Thingiverse (free) if you don’t want to design from scratch.

3. How do I choose between FDM, SLS, and MJF for my one-step project?

Use this quick guide:

• FDM: Best for low-cost prototypes (e.g., a plant pot) or parts that don’t need high strength.
• SLS: Best for durable end-use parts (e.g., a gear) that need to handle wear.
• MJF: Best for high-accuracy parts (e.g., a medical component) or small batches (20+ units) where speed matters.