Polyjet 3D Printing Explained
PolyJet printing—also known as material jetting—is an additive manufacturing technology that creates parts with a distinctly smooth surface finish.
The printing process involves layer-by-layer deposition of liquid photopolymer material, which is then cured under UV light. This method allows for faster production times and the use of multiple materials compared to other 3D printing methods like SLA.
The printer creates layers as thin as 16 microns – significantly thinner than many other 3D printing technologies. This level of detail and precision allows for complex geometries, intricate details, and various colors.
One of the critical advantages of PolyJet printing is its ability to print with multiple materials simultaneously, creating objects with varying material properties or colors. The result is spectacular-looking parts used by various industries.
How Polyjet Works
PolyJet was first introduced in the late 1990s by Objet Geometries, an Israeli company that later merged with Stratasys. Since its initial development, PolyJet technology has continued to evolve with advances in materials, print resolution, and multi-material capabilities.
At first glance, a PolyJet printing machine might look like a heavy-duty version of your office printer. PolyJet uses inkjet-like print heads to deposit droplets of liquid photopolymer resin on a build tray. These droplets are then cured with UV light, solidifying the material and creating a part layer by layer.
Support material plays a crucial role in PolyJet 3D printing, aiding in the creation of complex structures and ensuring the quality of delicate models. It is also designed for easy removal after printing, enhancing the overall quality of the finished product.
These printers utilize a combination of photopolymers, UV light, and inkjet print heads to build precise components layer by layer. The process begins with a CAD model, which is converted into a printable format. The printer then jets tiny droplets of photopolymer resin onto the build platform, which are immediately cured by UV lamps to form solid layers.
Support materials are used to uphold complex shapes and intricate details during printing and are later dissolved or manually removed, resulting in a finished PolyJet model that meets exact specifications.
A Polyjet printer.
Start Your Manufacturing Project with MakerVerse
MakerVerse is your platform for sourcing industrial parts, providing instant access to a vetted supply chain and a full range of manufacturing technologies. With AI-powered quoting, order management, and fulfillment, MakerVerse helps with everything from initial prototypes to full-scale production.
Applications of PolyJet
PolyJet is particularly useful for creating prototypes, models, and small-scale production runs. Advanced 3D printing technologies like PolyJet enable users to create prototypes that produce detailed and realistic models with versatile material properties.
Some of the standard applications:
Product design: Creating models and prototypes of new products to test and refine designs before moving to production.
Medical and dental: PolyJet is used to create models of teeth, bones, and organs for medical and dental applications. It can also be used to create surgical guides and other illustrative tools.
Aerospace: The technology can create models of aircraft parts and other components for testing and development.
Education: PolyJet is used to teach students through detailed visual models for various subjects.
This part, designed by Siemens Energy and produced by Makerverse, is a cosmetic prototype used to demonstrate gas flows and temperatures. Could you read more about this part in this use case?
Advantages and Disadvantages of PolyJet
PolyJet offers several advantages over other manufacturing technologies.
High level of detail and accuracy: PolyJet can create parts with a high level of detail and accuracy, with layers as thin as 16 microns.
The manufacturing process of PolyJet 3D printing technology allows for customization of material properties and emphasizes precision in creating prototypes, making it advantageous over traditional methods.
Wide range of materials: It can use a variety of photopolymer resins, including flexible, rigid, and transparent materials, allowing for parts with different material properties and colors.
Printing multiple materials simultaneously: PolyJet uses numerous print heads with different materials, creating objects with a mix of properties or colors.
Smooth surface finish: It produces parts with a smooth surface finish, reducing the need for post-processing.
Speed: This technology can produce parts relatively quickly, making it ideal for rapid prototyping and small-scale production runs.
However, there are some disadvantages to consider. These include:
Higher cost: PolyJet printing can be more expensive than other 3D printing technologies, making it less accessible to some users.
Limited material properties: If you need a part built to withstand difficult conditions, such as high temperatures, PolyJet isn’t an ideal technology.
Not suitable for large-scale production: PolyJet is ideal for rapid prototyping and small-scale production runs. However, its slower printing speed compared to other technologies makes it not always suitable for large-scale production.
Cost of PolyJet
The cost of using PolyJet technology varies depending on several factors, such as the size and complexity of the part, the material used, and the number of parts produced. PolyJet tends to be more expensive than other 3D printing technologies, such as FDM.
When deciding whether to use PolyJet, consider the project’s specific needs and whether the benefits outweigh the higher cost. For example, let’s say the project requires a high level of detail or a material not available with other technologies. In that case, PolyJet may be the most cost-effective option.
Materials and Support Materials Used in PolyJet
PolyJet uses photopolymer resins, liquid materials that harden when exposed to UV light. Several photopolymer resins are available, each with its characteristics and properties. Understanding the polyjet technical specifications is crucial as they serve as guidelines rather than limitations, affecting the model’s final output in terms of shape, texture, and finish.
These include:
Standard resins: Standard resins are the most common type of photopolymer resin. They are available in various colors and have a smooth surface finish.
Flexible resins: Flexible resins are bendable and rubber-like, making them suitable for prototyping and testing flexible parts.
Bio-compatible resins: Bio-compatible resins are designed for use in medical applications, such as dental and orthopedic devices
Material Properties and Selection
PolyJet 3D printing offers an extensive range of material properties and selection options, making it highly adaptable to various applications.
The technology enables the creation of digital materials by blending different resin types, resulting in materials that can be either flexible or rigid, and supporting a vast array of color options.
Available materials include photopolymers, rubber-like materials, transparent materials, and biocompatible materials. The choice of material depends on the specific requirements of the project, such as desired shore hardness, elongation at break, and notched impact strength.
This versatility allows for the creation of multi-material prototypes and parts that meet precise functional and aesthetic criteria.
PolyJet 3D Printing vs. Other 3D Printing Technologies
When deciding on a manufacturing technology for your part, it’s essential to consider the specific benefits of each technology. Here’s how PolyJet compares to some of the most popular 3D printing technologies.
FDM (Fused Deposition Modeling) is one of the most popular 3D printing technologies, as it is relatively inexpensive and easy to use. FDM works by melting and extruding thermoplastic material, layer by layer, to create a 3D object. While FDM can produce parts quickly and with a large build size, it doesn’t offer the same level of detail and accuracy as PolyJet.
MJF (Multi Jet Fusion) is another 3D printing technology gaining popularity. MJF works by laying down a layer of powder material and then fusing it with a liquid agent. This process allows for parts with complex geometries and precise details.
SLS (Selective Laser Sintering) uses a laser to sinter or fuse powder materials to create a 3D object. SLS can produce parts with high accuracy and detail and can use a wide range of materials. However, PolyJet is capable of even more detail.
Get Started with PolyJet
PolyJet 3D printing technology offers many advantages: high accuracy and the ability to print multiple materials simultaneously. Technology continues to evolve, so we expect to see even more advancements.
Are you ready to get a PolyJet part in your hands? Use the MakerVerse platform to produce your part at the highest quality levels. Just upload your design file and choose the technology of your choice. With our vetted supply chain, you’ll get PolyJet’s full capabilities combined with the expertise of our team to help see your project through.
