PlastXnow Explains – Multi Jet Fusion Speed and Precision for Additive Series Production

For a long time, additive manufacturing was not considered suitable for mass production. Multi Jet Fusion is changing that. It allows designs to be implemented more quickly and components to be transferred directly to mass production.

For a long time, additive manufacturing was not considered suitable for mass production. That changed with the development of Multi Jet Fusion (MJF). The process bridges the gap between prototyping and mass production because it allows for the cost-effective production of both individual prototypes and small- to medium-sized production runs. 

In addition, the high printing speed, consistent component quality, and the elimination of the need for tools enable flexible and cost-effective production. This allows companies to bring new designs to market faster and transition components directly to mass production without the need for time-consuming retooling.

What is Multi Jet Fusion?

Multi Jet Fusion is an industrial 3D printing process for plastic parts developed by HP. It belongs to the family of powder-bed processes and is particularly well-suited for the rapid production of functional prototypes and small- to medium-volume production runs.

Differences from Laser Sintering

Multi Jet Fusion differs from selective laser sintering (SLS) in that the plastic powder is not fused point by point with a laser, but rather using applied melting and detailing agents as well as infrared energy. As a result, the printing process is faster and often yields better surface quality and more consistent part properties.

How does the MJF process work?

The MJF printing process consists of several steps:

• A thin layer thermoplastic powder —often nylon or TPU—is spread across a build platform.
• The inkjet print heads can then begin printing the first layer. To do this, they selectively apply a binder to the powder, tracing the contours of the part layer by layer. At the same time, an insulating liquid is applied to the contours of the object to define them more clearly. 
• Then the build plate lowers slightly, and another layer of powder is applied. This process is repeated until all layers are complete.

After printing, the part cools in the powder bed before the excess powder is removed and the finished part is retrieved. The part undergoes semi-manual cleaning at a post-processing station.

In the final step, the components are glass bead blasted. During this process, a high-pressure jet propels fine glass beads onto the components to smooth the surface and remove any remaining powder.

 The World of Materials in MJF

One of the most common MJF materials is polyamide 12 (PA12 or nylon). This high-performance plastic offers balanced mechanical properties and a high-quality surface finish. It also exhibits good chemical resistance and can be water-dyed. PA12 can be used to print waterproof MJF parts.

In addition, there are other possible materials, such as PA11 (better suited for ductile components) and polypropylene (PP).  

Comparison: MJF vs. SLS

A key difference is that MJF is faster, which tends to result in lower manufacturing costs. While cost is an important factor, other aspects must also be taken into account, such as resolution, surface quality, material and color selection, and mechanical properties:

• Resolution: With MJF, it is possible to produce smaller features down to 0.5 mm.  With SLS, on the other hand, depending on the material, “only” features between 0.75 mm and 1.0 mm are possible.  
• Surface quality: Theoretically, MJF is the preferred choice here, although both technologies produce parts with a grainy texture that may require post-processing.
• Materials: Nylon is the primary material used in both processes. However, SLS can also process other materials, such as carbon- or glass-filled PA, which offer additional mechanical properties.  
• Color:  SLS is clearly the favorite here, as it allows parts to be produced in virtually any color. MJF, on the other hand, has limitations in this regard. As a result, parts manufactured using MJF have a slight grayish tint, but the manufacturer can color them black upon request.
• Mechanical Properties: Here, too, MJF appears to be the preferred technology at first glance, as it generally yields more consistent mechanical properties. For parts with critical features on multiple surfaces, MJF may be the better choice.

AdditivX | September 22, 2026

Additive Manufacturing as a Tool for Supply Chain, Production, and Service

The conference aims to demonstrate how 3D printing with plastics and metals can be used as a strategic tool for spare parts—regardless of the industry. The focus will be on materials, processes, cost-effectiveness, and integration into existing production and maintenance structures, including those from other areas of additive manufacturing.

Key topics of the event:

• Additive Transformation @ Daimler Truck & Buses (Keynote)

• What material and process requirements must a high-performance material meet in additive manufacturing?

• Digital Spare Parts Inventory: Fiction or Reality?

• Guided Tour of the SKZ Technical Center

Book a ticket now

Where is MJF used?

Multi Jet Fusion is used in any application where strength and moderate heat resistance are required. These include: functional prototypes, housings and covers, brackets and assembly aids, replacement parts, small-batch production, and customized products, as well as medical and industrial components.

Real-World Example: FPV Drones

The U.S.-based drone manufacturer Unusual Machines is using the HP Multi Jet Fusion for the production of its FPV drones. The company plans to use this technology to shift the manufacturing of components such as housings, connectors, and smaller parts for its SkyLite series to the United States. Read more at www.autocad-magazin.de

Summary

Multi Jet Fusion is a fast and precise industrial 3D printing process for plastics. It is particularly well-suited for durable functional parts and the cost-effective production of small- to medium-volume runs, and often offers a better combination of speed, surface quality, and mechanical properties than many other plastic 3D printing processes.