Prusa on local value creation: simple processes and rapid iteration

Josef Prusa, founder and CEO of Prusa Research, outlines his vision for a manufacturing strategy in a recent blog post. The tenor: more local value creation, less dependence, and practical technology instead of show effects.

Prusa sees FFF printing as a viable option for medium-volume series production. The main reason for this is the tooling costs involved in injection molding. According to Prusa, molds cost tens of thousands of euros. Injection molding only becomes worthwhile for him at around 60,000 units. Below that, 3D printing scores points with short iteration cycles, low start-up costs, and stable process windows.

The second focus is on mechanics. Prusa describes the principle as “low-tech high-tech”: bent sheet metal, standard connectors, and clear tolerance chains. The machine chassis serves as an exoskeleton and provides the supporting structure. Such parts can be manufactured worldwide. This simplifies supply, reduces complexity, and improves reparability because standard tools are sufficient.

Prusa emphasizes process discipline for additive series. The focus is on material qualification, fixed print profiles, and reproducible print farms. Where necessary, reworking is carried out by milling or thread inserts. Design for Additive Manufacturing reduces the number of components and assembly time. This allows functions to be integrated without losing robustness. Prusa has been producing parts according to this model for years.

He cites the new Core One as an example. The sheet metal exoskeleton facilitates local procurement in the US once the supply chain is in place. At the same time, he warns against dependencies and IP risks. He sees additive manufacturing as a key strategic technology that makes locations more resilient.

Prusa’s conclusion is sobering: it is not complexity that creates value, but resilient architecture and the ability to adapt components quickly. 3D printing and simple, universally available processes form the perfect tandem for this. It does not replace mass production, but it shifts the point at which injection molding becomes economical and strengthens local production.