PolyJet is an industrial 3D printing technique that creates multi-material prototypes with flexible elements and complex geometries in as little as one day. It offers a variety of hardness levels (durometers), making it ideal for components with elastomeric properties, such as gaskets, seals, and housings.

Typical applications for PolyJet 3D printing include:

  • Prototyping designs for overmolding or silicone rubber components
  • Merging two colors or hardness levels into a single part
  • Simulating elastomers or flexible materials

PolyJet Design Recommendations and Features

Our essential guidelines for PolyJet cover key design factors to optimize part manufacturability, improve visual quality, and minimize production time.

US Metric
Maximum Part Size 19.3 in. x 15.4 in. x 7.9 in. 490mm x 390mm x 200mm
Layer Thickness 0.00118 in. 30 microns
Minimum Feature Size 0.012 in. 0.3mm
Minimum Freestanding Wall, Hole, or Channel Size 0.030 in. 0.76mm

PolyJet Tolerances: For parts that are well-designed, typical tolerances are ±0.005 inches (0.1mm) for the first inch, plus an additional 0.1% of the nominal length. However, tolerances can vary depending on the geometry of the part.

PolyJet Material Choices

PolyJet offers the flexibility to select a specific hardness or combine various material properties within a single build, making it perfect for prototyping overmolding parts. Available Shore A hardness options include 30A, 40A, 50A, 60A, 70A, 85A, 95A, and rigid. These materials come in the following colors:

  • Digital Clear/Translucent
  • Digital Black
  • Digital White

PolyJet Material Property Comparison

Material Tensile Tear Strength Tensile Strength Elongation
30A 85 psi 399 psi 245%
40A 100 psi 508 psi 200%
50A 114 psi 508 psi 190%
60A 121 psi 580 psi 160%
70A 185 psi 725 psi 130%
85A 341 psi 1,088 psi 80%
95A 398 psi 1,740 psi 60%
Rigid n/a 8,702 psi 17.5%
Material Tensile Tear Strength Tensile Strength Elongation
30A 0.59 MPa 2.75 MPa 245%
40A 0.69 MPa 3.5 MPa 200%
50A 0.79 MPa 3.5 MPa 190%
60A 0.83 MPa 4.0 MPa 160%
70A 1.28 MPa 5.0 MPa 130%
85A 2.35 MPa 7.5 MPa 80%
95A 2.74 MPa 12.0 MPa 60%
Rigid n/a 60.0 MPa 17.5%

These values are estimates and may vary based on several factors, including machine settings and process conditions. As such, the information provided should not be considered final or certified. For critical performance requirements, we recommend independent lab testing of the materials or finished parts.

Our PolyJet 3D Printers

We operate several advanced additive machines that deliver large build volumes, precise parts, and fast production cycles. Our PolyJet machines include:

  • Objet260 Connex3
  • Objet350 Connex3

How PolyJet 3D Printing Works

The PolyJet process starts by jetting tiny droplets of liquid photopolymer onto the build platform, which are immediately cured with UV light. Voxels (3D pixels) are carefully deposited throughout the build, enabling the combination of flexible and rigid materials, known as digital materials. Each voxel has a thickness of 30 microns. As layers of digital materials are added, they form precise 3D-printed parts.

During the printing process, each part is surrounded by support material, which is later removed by hand using a pressurized water jet and a chemical solution bath. No additional curing is necessary after printing is complete.

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