Our quotes range between $5-12K USD for tooling, and $3-5 USD per part, $17K-20K USD total, giving us an estimated 500 units to sell before breaking even at expected retail of $40 USD, if we ordered 500-1000 parts. The math is loose, and we're not taking into account all costs, marketing, a store's cut, etc.

We are developing our first product, which is currently at the functional prototype stage. For the next step, we're looking to injection molding, and are working with some vendors to optimize our design for the process and for cost.

The design itself is simple, and we're flexible details, but it's basically a two piece shell with 3-4 countersunk recesses for screws on one side and corresponding bosses to thread into. There are standoffs for a PCB, and some other incidental features to position a battery. The walls will be normalized at 1.3-2.2mm, with about 80mm x 40mm overall dimensions.

A subreddit for anyone in the manufacturing industry. Content is very diverse: you'll find videos, articles and self posts just to name a few.

All that being said, before we pull the trigger on injection molding, I wanted to check if there were any options we may have missed for smaller-run manufacture of these plastic parts, that might have lower cost front-loaded into them. I've looked into things like vacuum molding with silicone molds, and some of the more professional 3D print methods, but had the impression these would be suitable for demonstration purposes (trade shows, promotional materials, etc.) and not to consumer products.