What is PolyJet technology and how does it work?

PolyJet technology is a cutting-edge 3D printing technique that has changed the world of additive manufacturing. It is known for its high precision, versatility, and ability to create smooth and detailed parts. In this article, we will dive into what PolyJet technology is, how it works, its advantages, and the wide range of industries and applications.

What is PolyJet technology?

This popular 3D printing technology is an advanced 3D printing process that uses photopolymer resins to create highly detailed and precise objects. It has the ability to print with multiple materials and colors simultaneously. This enables the creation of complex, multi-material prototypes or functional parts.

History of PolyJet technology

PolyJet technology was developed by the company Objet Geometries Ltd. Objet was incorporated in 1998 and was based in Rehovot, Israel. In 2009, Objet debuted their first printer. In 2012 Stratasys and Objet merged. Stratasys uses Objet as one of their brands of PolyJet machines, like the Objet 30.

How does PolyJet technology work? 

PolyJet technology works very similarly to your desktop 2D paper printer. Instead of jetting various colored inks PolyJet printers’ jet various photopolymers. These photopolymers are cured/hardened when exposed to UV light. The print bed is then lowered, and the process is repeated until a part is created layer by layer.

PolyJet 3D printer bed

Where parts have steep angles or overhangs a gel-like support material is used. A few different support material options are available depending upon the machine used. Support options dictate how the support is removed. Support can be removed with a jet of water, effectively spraying off the support material. Support material can be dissolved away with a caustic soda solution. A recently released support material option, WSS150, allows for the support material to be dissolved in water. Each support material and removal method come with its own pros and cons. Careful consideration must be given to ensure the success of your part.

Advantages of PolyJet technology:

• High fidelity parts with excellent detail and resolution
• Multiple materials and colors on the same build plate
• Wide variety of materials available including biocompatible
• No post cure needed
• Pantone Validated Colors

Realistic prototypes created with PolyJet technology

Disadvantages of PolyJet technology:

• Materials are subject to UV light and heat degrading
• Mechanical properties can be less than that of other technologies
• Support material leaves a matte finish on part

Industries and Applications of PolyJet

PolyJet technology has a wide range of applications. It’s used in industries including consumer goods, electronics, toys, figures, packaging, and entertainment. PolyJet technology is also widely used in the dental and medical field as well. PolyJet 3D printing is a great fit whenever highly accurate, realistic parts are needed.

Medical

In a field where innovation saves lives it’s easy to see why more hospitals and academic medical centers are adopting 3D printing into their workflows. PolyJet printers like the J5 MediJet and J850 Digital Anatomy are tailor-made for this application. PolyJet printing can create realistic anatomical models that can be customized for a variety of training purposes. These versatile models can be created quickly and cost less than traditional training aids.

Functional medical model

Without 3D printing surgery consisted of looking at scans on computer screens and trying to imagine how the surgery would be performed. With the utilization of PolyJet printing, patient specific models can be printed with multiple materials and colors to closely represent what the surgeon may encounter in a tangible 3D model. The PolyJet printed models allow for better planning, which could result in quicker surgeries and better success rates.

Read more about a medical 3D printing in this article >>

Dental

In the dental industry, traditionally casting and creating molds of a patient’s teeth and gums has been a costly and labor-intensive process. With 3D printing reliable, detailed and accurate models are quick and easy to produce. Stratasys offers a line of dental specific PolyJet materials, MED670, MED690, and MED620. These materials are available on the J5 DentaJet, J700 Dental (MED670 only), and Objet 30 Dental Prime. There are numerous use cases such as clear aligner molds, surgical guides, implant models and orthodontic models. PolyJet dental printers can help reduce costs, streamline workflows and create dental parts faster and with greater accuracy.

Packaging

Packaging designers around the world use PolyJet technology to quickly iterate and validate detailed, full color and multi-material packaging prototypes. A tangible and realistic prototype can help the designer receive valuable feedback to produce a better final product. PolyJet technology gives part realism in one step with little to no post-processing. Stratasys PolyJet printers support GrabCad print which can import full color 3MF files to quickly go from digital design to full color 3D print. PolyJet is a great fit for the packaging design of cosmetics, beverages, and consumer goods. Full transparency, graphics, colors, text and labels printed on site within hours.

Beer bottle VeroUltra

Toys/Figurines

Toys and figurines are a huge business segment and are bought and sold based on how they look. Getting the correct shape and color are paramount. Without 3D printing models are handmade and hand-painted with stickers and dry transfers applied to get the desired look. This process is time consuming and expensive. With PolyJet printing full color and full texture models can be printed in one shot for faster iterations and faster approval. Colors can be a subjective thing and if the superhero’s suit isn’t the exact shade it needs to be it is quickly noticed.

Pantone validated colors are part of the advanced color standardization system. Standardizing colors means that instead of someone trying to describe the desired yellow wanted, a bit darker than a dandelion, they can ask for Pantone 605. Stratasys J55 Prime, J7 series and J8 series of printers can print in Pantone validated colors with the Vero line of materials.

Toys VeroUltra

Consumer Goods

Last but not least on the list is consumer goods. The consumer goods industry is a big user of PolyJet technology. For the product development of consumer goods, PolyJet technology can simulate almost any material, woodgrain, leather, fabric, carbon fiber, etc. Which means independence from outsourcing and potential delays. Outsourcing part creation can be time consuming and expensive. The ability to create models in house with PolyJet saves time, money and very importantly keeps your company’s IP (intellectual property) safe.

Realistic prototypes created on PolyJet 3D printer

High fidelity parts, over half a million color options and digital materials allow for endless options only limited by your creativity. With PolyJet technologies, limitations often lie with the capabilities of the designer not with what the printer is capable of. If you are interested in adding a Stratasys PolyJet printer to your toolbox don’t hesitate to reach out. TriMech has a team of Solution Consultants that can help you with any questions or concerns you may have. TriMech also offers classes to help you learn to get the most out of your PolyJet machine.

Conclusion

PolyJet technology is a versatile 3D printing method that delivers high precision, multi-material capabilities. It is ideal for industries like aerospace, healthcare, automotive, and consumer goods that require intricate, smooth objects with a variety of material properties. While PolyJet offers many advantages like exceptional detail, and smooth finishes, it can be challenging with limited material properties and post-processing requirements. However, as 3D printing continues to evolve, PolyJet remains a top choice for many industries and applications.

For more information on PolyJet technology in product development, download our white paper Top Five Reasons to Integrate PolyJet Technology into your Product Development Lifecycle.