PolyJet is a powerful 3D printing technology developed by Stratasys that jets layers of liquid photopolymer droplets onto a build tray, curing each layer instantly with UV light. This inkjet-style additive manufacturing process enables unprecedented levels of detail, multi-material printing, and full-color capability — making it an essential tool for realistic prototyping, medical modeling, and complex product development.
How PolyJet 3D Printing Works
PolyJet works similarly to inkjet document printing, but in 3D. The print head contains hundreds of tiny nozzles that jet microscopic droplets of liquid photopolymer resin onto the build platform. As each layer is deposited, UV lamps on either side of the print head immediately cure the droplets, solidifying them into a precise, thin layer. The build platform lowers by one layer thickness (as fine as 16 microns), and the process repeats. Support material is jetted simultaneously for overhangs and complex geometries and can be easily removed with water jetting or manual peeling. The result is a fully cured part that requires no additional post-curing.
Key Advantages of PolyJet 3D Printing
Multi-Material and Full-Color Printing
PolyJet is unmatched in its ability to print multiple materials and colors in a single build. Digital materials can be created by blending different resins in specific ratios, producing parts with varying Shore hardness, flexibility, and opacity — all within the same print. Full CMY color capability enables photorealistic prototypes.
Exceptional Detail and Surface Finish
With layer thicknesses as fine as 16 microns (0.016 mm), PolyJet produces the smoothest surfaces and sharpest details of any 3D printing technology. Parts emerge with a near-injection-molded surface quality, requiring minimal or no post-processing for presentation-ready results.
Wide Range of Material Properties
PolyJet materials span from rigid and transparent to rubber-like and biocompatible. With digital material blending, over 500,000 color and material combinations are possible. This enables overmolding simulation, where rigid and flexible materials are combined in a single part to replicate multi-shot injection molding.
Office-Friendly and Fast
PolyJet is a clean, safe process with no loose powder or chemical baths. Parts are fully cured during printing and ready to handle immediately. Small to medium builds can complete in hours rather than days, enabling rapid design iterations.
PolyJet 3D Printing Materials
| Material Type | Key Properties | Typical Applications |
|---|---|---|
| Vero (Rigid Opaque) | Stiff, strong, detailed, multiple colors | Visual prototypes, consumer product models, assembly testing |
| VeroClear (Transparent) | Optical clarity, polishable to transparency | Light pipes, lenses, fluid flow visualization, transparent housings |
| Agilus30 (Rubber-like) | Flexible, Shore 30A-95A, tear resistant | Soft-touch grips, seals, gaskets, wearable prototypes |
| Digital ABS (Engineering) | High toughness, heat resistant, impact resistant | Functional prototypes, snap-fits, thin-walled enclosures |
| Biocompatible (MED610) | ISO 10993 certified, sterilizable | Surgical guides, dental trays, medical device prototyping |
| High Temperature | HDT 65-80°C, thermal resistant | Hot air flow testing, thermal form/fit, under-hood prototypes |
Common Applications of PolyJet
- Realistic Prototypes: Full-color, multi-material prototypes for design reviews, ergonomic evaluation, and consumer testing
- Medical Modeling: Patient-specific anatomical models with multi-tissue representation, surgical planning guides
- Overmolding Simulation: Parts that combine rigid and flexible materials to replicate overmolded product designs
- Tooling and Molds: Injection mold inserts for low-volume production, silicone molding patterns
- Packaging Prototypes: High-fidelity packaging mock-ups with labels printed directly on the part
- Dental: Crown and bridge models, orthodontic aligner models, dental implant guides
PolyJet vs Other Technologies
PolyJet stands apart through its multi-material and full-color capabilities, which no other single 3D printing process can match. Compared to SLA, PolyJet achieves finer layer resolution (16 vs 25-100 microns) and produces parts with multiple material properties in one build. Versus SLS, PolyJet provides superior surface finish and detail, though SLS offers stronger functional materials. Against MJF, PolyJet wins on color and multi-material options, but MJF generally has faster throughput for production volumes.
Frequently Asked Questions
What is the typical build volume for PolyJet 3D printing?
Professional PolyJet systems typically offer build volumes around 490 × 390 × 200 mm. Larger systems can achieve up to 1,000 × 800 × 500 mm. The build volume can be fully utilized for multi-part batches, though mixed-material builds may require additional clearance between parts of different materials.
Can PolyJet parts be used as end-use products?
While PolyJet excels at prototyping, certain materials like Digital ABS and biocompatible resins can be used for end-use applications. However, PolyJet materials generally have lower UV stability and thermal resistance compared to SLS or injection-molded thermoplastics, making them better suited for indoor, moderate-temperature applications and short-run production.
How durable are PolyJet parts over time?
PolyJet parts maintain their mechanical properties well under normal indoor conditions. However, prolonged UV exposure can cause yellowing and embrittlement. For outdoor or high-temperature applications, material selection and protective coatings should be considered. Vero materials maintain dimensional stability better than flexible materials over time.
What is the typical lead time for PolyJet parts?
PolyJet printing is relatively fast, with small-to-medium builds completing in 4-24 hours. Combined with minimal post-processing, standard lead times are typically 3-5 business days. For single parts or small batches, next-day delivery is often achievable.