PolyJet 3D Printing

How Does PolyJet 3D Printing Work? 

PolyJet is photopolymer-based jetting process that distributes fine material droplets, layer-by-layer, onto a build platform. It can print multiple materials plus a support material at the same time. A flash of UV light immediately cures the material droplets.

PolyJet is known for its ability to print striking colors and ultra-fine details. By combining photopolymers in different concentrations and structures, it can simulate plastics, rubber and other materials, with textures and patterns that aren’t possible with any other 3D printing method. That enables you to create incredibly detailed prototypes and models that incorporate a variety of material properties and aesthetics.

At the end of the build process, the part is ready for use. No post-processing is required. The gel-like support material can be removed using a water jet, eliminating the need for time-consuming support structure removal.

Applications of PolyJet 3D Printing

Rapid and functional prototypes: Create smooth, detailed prototypes with ultra-fine details and surface textures that simulate the aesthetics of your product.

Visual aids and models for presentation: Because PolyJet can combine different materials, colors and transparencies, it’s a favorite technology for creating detailed, realistic medical and dental models.

Complex parts with precise dimensions: PolyJet has a minimum layer thickness of 16 microns. Its ability to capture tiny details with a high degree of dimensional accuracy is like nothing you’ve seen before in the world of additive manufacturing.

Manufacturing tools: PolyJet isn’t just for printing pretty models. It can also be used to build molds, jigs and fixtures where dimensional accuracy is a key requirement.

Flexible parts that simulate traditional elastomers: PolyJet is perfect for printing gaskets, seals and other parts where elastomer-like characteristics are a must.

Industries where PolyJet parts are used include:

• • Aerospace
  • Automotive
  • Medical
  • Dental
  • Consumer products
  • Art and fashion

What Does PolyJet 3D Printing Make Possible?

Design freedom: Choose from hundreds of materials and hundreds of thousands of color combinations to bring your product ideas to life.

Simplify your part production: PolyJet printers have multiple print heads that can lay down multiple materials with different durometers and a support material at the same time, within a single part build. In other words, a PolyJet printed part can contain sections that are hard and soft. The effect is similar to overmolding but is less expensive and much faster.

Don’t sweat the details: Most 3D printing technologies deposit or sinter a layer of material at a time. In contrast, Polyjet lays down droplets of photopolymer to build your parts. The layers are incredibly thin, which means your parts can contain ultra-fine details, rendered with a fidelity and accuracy that other types of 3D printing can’t equal.

Fast part production: For smaller build volumes, PolyJet is a relatively fast 3D printing process. Plus, parts don’t require curing. Removal of support structures is quick and easy. You can get your parts in as little as one day!

Advantages 

Versatile and fast: From prototypes and colorful models to end-use parts, PolyJet does it all. It can print them quickly, giving you more time to design, test and perfect your designs.

Excellent level of detail: PolyJet can print layers as thin as 16 microns. That means parts produced using it can contain an extraordinary amount of detail and an excellent surface finish.

Support for digital materials: PolyJet printers can mix up to six resins, which gives designers and engineers unprecedented creative opportunities to fine-tune their part designs and material characteristics.

Transparent options: PolyJet can print transparent materials that enable the production of transparent and translucent parts.

Fast removal of support material: The gel-like support material used by PolyJet is water soluble. It can be dissolved using a water jet. This eliminates the need for time-consuming post-production processes and results in a smoother part finish than some other 3D printing processes.

Strong parts: PolyJet can produce sturdy parts that have good tensile strength.

Disadvantages 

Cost: The materials required for PolyJet printers tend to be more expensive than those for many other types of 3D printing.

Part size limitations: PolyJet isn’t suitable for printing larger parts. The maximum build size for Fathom’s PolyJet printers is 19.3 x 15.35 x 7.9 in.

Consider the environment where the parts will be used: Exposure to heat, sunlight and humidity may affect the characteristics of PolyJet materials over time.

Alternatives/What Can PolyJet be Paired With?

PolyJet is sometimes used to create work holding fixtures where precise positioning of a product being manufactured is a must.

Polyjet parts can be post-machined to meet specific tolerances. They can also be bonded to other assemblies, such as fiberglass panels, and other additive parts.

Alternatives to PolyJet:

• • If precise tolerances aren’t required, FDM and SLS are viable alternatives for creating jigs and fixtures.
  • SLA can be used for both functional prototypes and parts, which makes it a potential alternative to PolyJet.
  • Multi-Jet Fusion (MJF) can produce complex geometries with excellent surface finishes, similar to PolyJet.
  • Selective Thermoplastic Electrophotographic Process (STEP) technology provides good surface quality and excellent small feature details.

Traditional technologies that could benefit from PolyJet

Prototype parts are made using a variety of techniques. Having a tool built to produce a handful of prototype injection molded parts could take weeks. CNC machining prototype parts requires time-consuming machine and work holding tool setups and a skilled operator. In contrast, PolyJet can be used to print prototype parts in a matter of hours.

Many types of visual aids and models are now made by hand using clay, screen printing, labels and other time-consuming and often expensive manual techniques. These models can be produced much faster using PolyJet. Inks are available in thousands of colors and can be controlled at the voxel level. It can also print a variety of surface textures. That means you can create sophisticated prototypes that exactly match the look and feel of your brand.

PolyJet Materials Available 

PolyJet 3D Printers use photopolymers that can simulate different material properties ranging from rubber to rigid and transparent to opaque. Some materials are very hard and are heat resistant. Others have the feel of a rubber or elastomeric material that can flex, bend and act as a seal.

Digital materials expand the possibilities by blending two or more base resins to create thousands of material combinations. Customers can achieve full color capabilities, translucencies, Shore-A values, and other properties for maximum realism in product designs.

Not sure what you need? Talk to a Fathom expert today!

Check Out These PolyJet Printed Parts 

Finishing Option for PolyJet Parts

Parts produced using PolyJet can be painted or dyed and coated with a clear lacquer or polyurethane finish to provide a high-gloss finish, protect them from damage and to prevent moisture damage. These parts have smooth surfaces and crisp details. That means little or no sanding or filling is needed prior to painting.

Why choose PolyJet 3D Printing?

• • If you need to create a colorful, 3D visual aid or presentation model, the fastest and highest fidelity way to create it is with PolyJet 3D printing.
  • If you need to create a prototype part with fine detail and an excellent surface finish, PolyJet is the right additive solution for you.
  • If it’s desirable to have more than one type of material, texture or durometer incorporated into a single part, PolyJet is the only additive technology that can do that.
  • If you need fixtures that must match specific tolerances for your manufacturing operation, PolyJet may be the best choice for you.

Why Choose Fathom’s PolyJet 3D Printing Capabilities? 

Fathom has multiple PolyJet printers at its Hartland, WI facility and the capacity to print your parts quickly. We also offer full post-processing capabilities under one roof. Get all your PolyJet production needs met in one place.

Get a PolyJet 3D Printing Quote

Get a quote on your PolyJet project with our SmartQuote platform.

Additional Resources 

Rapid prototyping
Fathom additive manufacturing services
3D printing vs. injection molding
Design and engineering support
Finishing and post-processing