Polyjet 3D Printing Explained
Looking for highly-detailed parts with a smooth finish? Learn all about what PolyJet printing can and can’t do.
PolyJet printing—material jetting—is an additive manufacturing technology that creates parts with a distinctly smooth surface finish.
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 colours.
One of the critical advantages of PolyJet printing is its ability to print with multiple materials simultaneously, creating objects with varying material properties or colours. By utilizing digital materials, designers can create complex and detailed prototypes with various textures, colours, and functionalities that are impossible with single-material printing technologies. The result is spectacular-looking parts used by multiple industries.
What is PolyJet 3D Printing?
PolyJet 3D printing is a cutting-edge multi-material jetting photopolymer technology with unparalleled precision and versatility. This advanced 3D printing method is ideal for everything from prototyping to production, enabling the creation of complex geometries, intricate details, full-colour combinations, transparencies, and flexible parts—all within a single model. By merging the strengths of both plastic and powder-based technologies, PolyJet 3D printing brings innovative ideas to life with exceptional accuracy and detail.
PolyJet Technology Overview
PolyJet technology, a patented innovation by Stratasys, stands out from other 3D printing methods due to its unique approach. This technology combines power, speed, quality, reliability, and flexibility in one seamless printing process. PolyJet printers use liquid photopolymers, jetted onto a build tray in ultra-thin layers. These layers are then cured with UV light, solidifying the material and building the model layer by layer. With the ability to achieve accuracy as fine as 0.1mm, PolyJet printers produce smooth surfaces and thin walls, making them ideal for detailed and high-quality prints.
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. The use of gel-like support material enables the printing of complex geometries and easy removal of supports without damaging intricate details.
Multiple print heads in PolyJet technology allow for the simultaneous deposition of different materials and colors. This capability enables the creation of multi-material and multi-color parts, enhancing both the functionality and aesthetics of the 3D printed objects.
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Applications of PolyJet with Multiple Materials
Polyjet is particularly useful for creating prototypes, models, and small-scale production runs. Some of the standard applications:
Product design: Creating models and prototypes of new products to test and refine designs before moving to production. The use of multi-material prototypes allows for testing and refining designs with various colors and material properties in a single print process, simulating real-world applications.
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 use of support structures is essential for achieving complex geometries and ensuring dimensional accuracy, especially for intricate designs.
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 colours. Additionally, the use of support materials in PolyJet printing contributes to the efficiency and quality of the final prototype, as these materials can be easily removed post-printing.
Printing multiple materials simultaneously: PolyJet uses numerous print heads with different materials, creating objects with various properties or colours.
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 challenging 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 than other technologies makes it unsuitable 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 Material Used in PolyJet
PolyJet uses liquid photopolymer material, which hardens when exposed to UV light. This material is deposited layer by layer and cured with UV light, allowing for the simultaneous printing of different materials and colours. Several photopolymer resins are available, each with its characteristics and properties.
These include:
Standard resins: Standard resins are the most common type of photopolymer resin. They are available in various colours 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 orthopaedic devices
PolyJet 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.
Understanding PolyJet technical specifications is crucial for designing prototypes effectively. These specifications provide a framework to guide users in utilizing PolyJet technology, as the final output can vary in shape, texture, and finish despite accurate CAD models.
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 that is 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.
Choosing the Right PolyJet 3D Printer
Selecting the right PolyJet 3D printer depends on various factors, including the materials you plan to use, the size of your prints, and the required level of detail. A compact PolyJet 3D printer offers an affordable solution for those working with single materials. However, larger stand-alone PolyJet printers are more suitable if your projects demand multiple materials. For instance, the Objet30 V5 series is the smallest and most cost-effective option, while the J4100 is the largest PolyJet printer, capable of handling models weighing up to 135kg on the printing plate.
PolyJet 3D Printing Services
PolyJet 3D printing services are available online, providing on-demand solutions for prototypes and large production batches. With the ability to deliver PolyJet 3D printed parts in as little as seven days, Makerverse makes bringing your designs to life easy. Upload your CAD files to Makerverse`s Instant Quoting Engine to receive an instant quote and explore various manufacturing options tailored to your needs.
Real-World Examples and Case Studies
PolyJet 3D printing has applications across various industries, including aerospace, automotive, dental, medical, and consumer goods. In the medical field, PolyJet technology creates highly realistic anatomical models for teaching and surgical planning. These models look lifelike and mimic the feel and response of human tissues. In the automotive and aerospace sectors, PolyJet 3D printing is employed to produce complex prototypes with intricate details, such as engine parts and customized designs. Whether it’s a smartphone case or a sophisticated component for a bicycle, PolyJet 3D printing delivers exceptional detail and functionality.
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.
