PolyJet

PolyJet (material jetting) 3D prints smooth, high-detail plastic parts by jetting and UV-curing photopolymer droplets, including multi-material and full-color builds.

Overview

PolyJet is a material jetting 3D printing process that jets microscopic droplets of liquid photopolymer and UV-cures them layer-by-layer. It delivers very fine features, sharp edges, and some of the best as-printed surface finish in plastics, with the ability to print multiple materials in one part (rigid, rubber-like, and clear) and, on some systems, full color.

Choose PolyJet for appearance models, ergonomic prototypes, and assemblies where you need realistic feel, overmolds/soft-touch regions, transparency, or color labeling. Expect support material that must be removed from cavities and small channels, and parts that behave like UV-cured resins: good for fit/finish and light functional use, weaker in long-term heat/UV exposure and less impact/fatigue durable than true thermoplastics. Large parts can be costly, and watertight or very small internal passages are hard to clean reliably.

Common Materials

  • Vero (rigid photopolymer)
  • Agilus30 (rubber-like photopolymer)
  • Tango (rubber-like photopolymer)
  • MED610 (biocompatible photopolymer)
  • Rigur (tough photopolymer)
  • Clear photopolymer (VeroClear)

Tolerances

±0.005 in (±0.13 mm) typical; ±0.010 in (±0.25 mm) on larger parts

Applications

  • Show-quality appearance prototypes
  • Overmold-style grips and seals (multi-material)
  • Transparent flow/fit mockups (clear parts)
  • Ergonomic handles and UI models with color labels
  • Snap-fit and enclosure fit-check prototypes
  • Surgical guides and medical device mockups (material-dependent)

When to Choose PolyJet

PolyJet fits best for low-quantity prototypes where surface finish, fine detail, and multi-material or color matter more than maximum mechanical strength. It’s a strong choice for fit/feel validation, cosmetic models, and soft-touch features printed in one build. Plan on post-processing for support removal and treat the parts as photopolymer prototypes rather than end-use thermoplastic hardware.

vs Fused Deposition Modeling (FDM)

Choose PolyJet when you need smooth surfaces, crisp small features, and accurate cosmetic geometry without heavy sanding. PolyJet also supports multi-material (rigid + elastomer) and high-quality clear/color outputs that FDM typically can’t match.

vs Stereolithography (SLA)

Choose PolyJet when you need multiple durometers/materials in one part, digital “overmold” features, or full-color labeling. PolyJet also tends to deliver very consistent surface quality across complex exteriors, while SLA is usually single-material per build.

vs Selective Laser Sintering (SLS)

Choose PolyJet for show surfaces, transparency, fine edge definition, and soft-touch regions. SLS is better when you need tough, ductile nylon parts and complex internal voids without support removal constraints.

vs Digital Light Processing (DLP)

Choose PolyJet when you need multi-material behavior (rubbery + rigid) or full color in one print. DLP is typically a better fit for single-material resin parts where you want faster throughput or higher temperature resin options, but it won’t replicate overmold-like assemblies as directly.

vs Multi Jet Fusion (MJF)

Choose PolyJet when appearance and tactile realism drive the decision—smooth, detailed surfaces and elastomer-like sections in one build. MJF is better for durable nylon parts and higher-volume prototype runs, but it won’t deliver PolyJet’s clear/color/multi-durometer capabilities.

Design Considerations

  • Avoid long, small internal channels and blind cavities where support material can’t be fully removed
  • Call out which surfaces are cosmetic and their orientation preferences; surface finish varies by face and support contact
  • Use realistic minimum wall thicknesses for thin fins and tabs, and thicken areas that must survive handling during support removal
  • Specify target durometer/feel for soft regions and clearly define rigid-to-soft boundaries to avoid ambiguous material blends
  • Add drain/cleanout access for any enclosed volumes and design clear paths for support evacuation
  • Dimension critical fits after post-processing; allow clearance for support removal and slight dimensional variation on larger parts