In today’s blog post I’ll be sharing a few tips about how you can choose between machine and hand-made product replicas. First, I’ll explain what both of these options are. Before presenting the key differences regarding cost, time, customization and quality.
At the end I’ll recommend which of these two product replicas you should choose when and how to choose the right production for your project.
Machine-made replicas are products that, to a high degree, are made by machines. Instead of manual work. There exist a lot of machines that can create products. Which one is a good fit will depend on the type of replica. Its design. Its material. Its required level of quality. The budget. And the required lead time. We here at PES operate a broad range of machinery. Injection Molding. For shaping different types of plastic. 3D printing. CNC machines. Die casting. For shaping products made from ZAMAC, a zinc alloy. As soon as any of these technologies are involved, we’re usually talking about some type of bulk production process. Although both 3D printing and CNC technology are often used for creating one offs, e.g. prototypes and samples.
Hand-made replicas are replicas made by manual labor. If at all, there is very little machine involvement in the process of making the product. The focus is on artistic expression or craftsmanship.
Besides operating a broad set of machinery, we here at PES make a lot of products by hand. Even when we make replicas with the help of a machine, there are usually several production steps involved which are performed by hand, e.g. brushing the surface of a metal product.
There exist a multitude of differences between hand-made and machine-made replicas. Depending on the type of project and a customer’s individual preferences, one decides what the better choice is. Often production processes will involve some form of both. Let’s dive into four of the key differences.
When clients send us a brief, they sometimes don’t mention how many units they need. This input is very important. Not only for determining the costs of production, based on which we are then able to quote the product, but for determining the best option of production. In terms of cost efficacy.
If, for example, you need a single custom trophy, we’ll seek design options which don’t require any custom tool to be developed. Why? Tools require a relatively high upfront investment. Which, financially, makes more sense for larger volumes. How much exactly will depend on the product type and individual design. For a keyring it might be 300 EUR and for a bottle opener 500 EUR.
There always exists a turning point. A number of units for which the math tells us, based on the price per unit, it now becomes more cost-effective to switch to another way of producing the item. This often means switching from a hand-made to a machine-made production process.
We here at PES are in the business of helping clients engage with consumers. We do so by crafting custom premium Point of Sale material and branded merchandise. A lot of our clients tell us that speed to market is often more relevant than price.
Think about this. If it can be done fast, price becomes less relevant. The important thing is to be faster than the competition. This means production planning and execution plays a major role in succeeding or failing. Hand-made production is usually slower than machine-made production. Particularly for larger volumes. The only exceptions are when a machine-made replica first requires a tool to be developed, e.g. from stainless steel. Tool development can take weeks or even months, depending on how complex the replica is. In such cases it will be faster to create the replica by hand.
When it comes to customization, hand-made products have an advantage. Because skilled craftsmen can adapt to special wishes. From size to materials to design details. If need be, each single unit can have small variations, e.g. an engraved name or some other personalized text.
Machine-made products only offer limited customization options. They represent the better option for mass production. Which result in products with a long durability and high precision. There is only little room for variation.
Most of the time skilled artisans will be able to offer products of a very high quality. The reason for this is, over time, they have carefully developed their skills and they pay attention to each detail.
This can relate to hand-polishing, painting and other finishing options that artisans opt for. Furthermore they have expertise when it comes to choosing premium materials. This has a positive impact on both aesthetic appeal and durability.
If the goal is to achieve a high level of uniformity between the different units, machines are the way to go. The durability is also higher. Another important aspect regarding quality is the efficiency of machine production. Less defects. Whilst producing faster.
There are several factors to consider before choosing a machine-made replica instead of a hand-made replica. First of all, your budget. If you hit a certain minimum order quantity, which will depend on the design and the manufacturing technology, but most of all on the supplier you work with, machine-made replicas should be much more cost-effective than hand-made ones.
Secondly, how important precision is for your replica. Machines can assure a very high level of uniformity which is needed for products such as e.g. furniture or collectibles. Another aspect that speaks for machine-made replicas is durability. Many machine-made products use modern materials that foster durability and functionality, which makes them a good option for daily use. Machine-made replicas are the better option when you have to work within a short timeline. Unless you only need a low number of units and, based on the product design, can avoid tool development. In this case choosing hand-made replicas might be the faster option.
There are multiple scenarios for which choosing hand-made instead of machine-made replicas will be a wise choice. Whenever you are working on a project for which artistic expression is important, you want to choose hand-made replicas.
Particularly if, from a marketing and branding perspective, it is important to communicate that a human being has created the products. These might even require a certain customization that is only viable if a human is creating the replicas.
If your project requires a high level of quality and extraordinary attention to detail, hand-made replicas will be the best choice. These are usually made from higher quality materials, carefully chosen by a craftsperson or artist. This gives you the chance to support artisans rather than factories, thus supporting small businesses. From a sustainability perspective, hand-made replicas are usually the better option because you’re investing into small scale rather than mass production. Mass production often means producing surplus units for which nobody might have a use.
There exist many options, regarding both the production method and the supplier, you can choose from. The key is to balance quality, budget and speed of delivery. It is usually impossible to find a solution if all three aspects need to be combined. With this I mean a high quality, a low investment and a fast delivery.
This means you need to define what is most important to you and pick a maximum of two out of these three.
Get knowledgeable about different production methods. You don’t need to become an expert but when you e.g. need a custom trophy made from metal, it helps to understand the difference between casting and CNC technology. Tap into the knowledge your supplier partners have. A conversation about the process of making replicas is already a start.
You might want to pick a partner who has a proven track record of producing both hand-made and machine-made replicas. Like us here in PES 😊. If a supplier has expertise in both areas, they’ll be able to assess which option is best for your specific project.
Here are a few questions I recommend you ask:
- What is your Minimum Order Quantity?
- Does your process include first providing samples? Be aware that there is a difference between a prototype and a PP sample. PP samples are done exactly like the later bulk produced units. Prototypes are not and therefore might be (quite) different.
- What are the branding and customization options?
- What is the lead time? Best to know this for each individual project phase, e.g. concept development, product development…
Be ready to share information about your budget and the number of units you seek to source with potential suppliers. This will help them determine which manufacturing technologies are the most cost-effective ones for your custom replica.
Even if you don’t have any prior experience related to the production of replicas, you’ll be able to figure it out. After all, there are just two main options to choose from. Either machine or hand-made.
As with many other services and products, working with the right supplier will be key here. One that has expertise and is willing to share their knowledge with you. So that, throughout time, you can learn more about how to choose the right type of replica for your project.
Ivica Baraba - Sales & Marketing management
"In PES I get to work on many custom branded merchandise projects. I’ve been doing this since 2004. It intrigues me to delve into brand worlds and determine what products can help a client achieve their business goals. It is an exceptionally creative and dynamic industry to be a part of.”
