PolyJet: Multi-Material Precision and High-Fidelity Realism
PolyJet technology stands alone in its ability to print multiple materials simultaneously, allowing for the integration of rigid, flexible, and transparent properties within a single monolithic part.
At Prototal, we leverage PolyJet to produce high-resolution prototypes that look, feel, and function like finished consumer products. Whether you need overmolded grips, living hinges, or simulated multi-shot injection molded parts, PolyJet delivers unmatched aesthetic and tactile accuracy without the need for assembly.
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| Feature | Prototal PolyJet Capability | Benefit |
|---|---|---|
| Max Build Volume | 490 x 390 x 200 mm | Efficient multi-material assembly production |
| Material Types | Rigid, Rubber-like, Transparent | Simulate multi-shot injection molding |
| Accuracy | Tolerance at 0.2 mm | Perfect for intricate cosmetic details |
| Shore A Range | From 27A (Soft) to 95A (Rigid) | Test different tactile feels in one part |
| Surface Finish | Smooth, high-gloss or matte | Professional and realistic finish |
Multi-Material Innovation
PolyJet technology bridges the gap between concept and functional realism by allowing for a diverse range of material properties in one build. By jetting layers of liquid photopolymer that are instantly cured by UV light, we can achieve ultra-thin layers for a surface finish that is exceptionally smooth and mimics multi-shot injection molding.
Industries benefiting from PolyJet:
- Electronics: Prototypes with integrated buttons and soft-touch grips
- Medical Technology: Anatomical models with varying tissue densities for surgical planning
- Product Design: Realistic look-and-feel models for ergonomic and tactile testing
- Industrial Engineering: Complex gaskets, seals, and connectors with varied Shore A hardness
Mastering Build Complexity
Our PolyJet systems offer a versatile build volume of up to 490 x 390 x 200 mm. This capacity allows for the production of multiple small, high-detail parts in a single tray or the creation of complex, multi-material assemblies as a single monolithic unit. By utilizing the full tray, we can deliver high-fidelity prototypes with significantly reduced lead times compared to traditional overmolding processes.
Digital Materials & Performance
PolyJet is unique in its ability to create “Digital Materials” by blending primary resins on the fly. This allows for precise control over color, transparency, and flexibility. While PolyJet is primarily used for high-fidelity prototyping and form-fit testing, these digital blends provide a level of aesthetic detail that is indispensable for stakeholder reviews and market validation.
Optical Clarity & Tactile Precision
The portfolio includes specialized resins for every functional requirement. Our transparent materials provide excellent clarity for light pipes and screens, while our rubber-like resins allow for a range of Shore A hardness from 27A to 95A. This versatility enables us to simulate everything from soft silicone to rigid thermoplastics within a single part, ensuring your prototype feels as real as it looks.
Advancing Pediatric Cardiac Surgery
In collaboration with a leading Danish hospital, we use PolyJet to produce patient-specific 3D models of children’s hearts. By simulating various tissue densities, we provide surgeons with a 1:1 replica to practice intricate procedures. To support these life-saving surgeries, we have optimized our workflow to deliver these models within 24 hours of receiving the scan data.
3D Printing Guidelines
Our helpful guides are specifically designed to assist you before submitting your design to us. We always strive to achieve the best possible outcome, and by following our guidelines, you can be confident that your design will be of the highest quality.
Get in touch with us if you need guidance, we are happy to help you!
How PolyJet Achieves Multi-Material Realism
The PolyJet process is a high-definition additive manufacturing method that functions similarly to an inkjet printer, jetting thousands of tiny droplets of photopolymer resin that are instantly cured by ultraviolet (UV) light.
The Step-by-step Process in PolyJet
- Digital Material Blending: Your CAD data is analyzed to assign specific properties, such as color, transparency, or flexibility, to different regions of the part. This allows us to create “Digital Materials” that simulate overmolding in a single build.
- Ultra-Fine Layer Deposition: The print head jets microscopic layers of liquid photopolymer onto the build tray. By utilizing layers as thin as 16 to 30 microns, the process captures intricate textures and achieves a surface finish with nearly invisible layer lines.
- Simultaneous UV Curing: UV lamps attached to the print head instantly solidify each droplet of resin as it is deposited. This immediate curing ensures high dimensional accuracy and allows for the production of complex, multi-material assemblies without warping.
- Gel-Support Removal: To protect overhangs and internal geometries, a specialized gel-like support material is printed alongside the part. After the build, this is efficiently removed using a water jet or a chemical bath, leaving the original surface intact and smooth.
- High-Fidelity Finishing: Once cleaned, parts are ready for immediate use or high-end finishing. For clear materials like VeroClear, this includes professional polishing to achieve optical transparency.
Bring Your Design to Life
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Quote Your Next Project
Looking for high-quality industrial 3D printing solutions tailored to your needs? Our team is ready to provide a detailed quote for your project. Simply share your specifications, and we’ll deliver a clear, competitive estimate — no surprises, just precision and reliability.
Why choose us?
- 3D printing solutions for any scale and complexity
- Fast and accurate quoting process
- Local presence close to your business and business needs
FAQs
Do you have questions regarding PolyJet Industrial 3D Printing? Find the most common questions and answers about the subject here.
Yes. PolyJet’s greatest strength is jetting multiple resins simultaneously, allowing for parts with varying colors, transparencies, and flexibilities (Shore A) in a single build.
Yes. As seen in our collaboration with local hospitals for pediatric cardiac models, PolyJet can simulate different tissue densities, making it indispensable for surgical planning and education.
Our systems feature a build volume of 490 x 390 x 200 mm, allowing for complex, multi-material assemblies in a single build.
With layers as thin as 0.16 mm, PolyJet offers one of the smoothest finishes in 3D printing. Layer lines are virtually invisible, mimicking the quality of injection molding. While we can professionally polish hard, rigid surfaces to achieve high transparency or a gloss finish, please note that soft, rubber-like elements cannot be polished due to the nature of the material.
We offer a range of post-processing services to ensure your 3D printed parts meet the highest standards of quality, precision, and aesthetics.
- Support removal & Sanding
- Threaded/non-threaded inserts
Manufacturing should not be transactional. At Prototal we value a partnership, which is why you will get a dedicated contact person close to your operations that knows your business and business needs. To start our future partnership, please reach out to the local team within your area that can be found under Contact us or send us an e-mail:
- Norway: post@prototal.no or +47 74 09 06 00
- Sweden: 3dp@prototal.se or +46 (0) 36-38 72 00
- Denmark: 3dp@prototal.dk or +45 43 99 37 36
- United Kingdom: info@prototaluk.com or +44 01635 635855
- Italy: info@prosilas.com or +39 0733 892665
- Austria, Germany & Switzerland: 3dp@prototal.at or +43 5572 52946-9
As a flexible partner we can offer lead times down to 1 working day depending on the selection of post-processing and quality control. Usually, you can expect a lead time within the range of 2-3 working days, depending on same variables as stated above.*
*While Prototal offers industry-leading turnaround times, all delivery schedules are estimates based on standard operating conditions. Final lead times are subject to local availability, part geometry, build volume, and specific material selection. Complex geometries requiring extensive support structures or high-performance materials may require additional processing time to ensure structural integrity and dimensional accuracy.
