PolyJet & 3D Printed Silicone (60-65%)

What is Polyjet?

Polyjet is a 3D Printing process that provides excellent accuracy as well as the ability to strategically alter material properties in a way not previously possible. It also allows for different colours and hardness level in a single layer, that is just a quarter of the thickness of a sheet of printer paper!

Polyjet uses a jetting process. Small droplets of liquid photopolymer, called voxels, are sprayed from multiple jets onto a build platform and cured in layers that form elastomeric parts.

PolyJet is an industrial 3D printing process that builds multi-material prototypes with flexible features and complex parts with intricate geometries in as fast as 1 day. A range of hardness's (durometers) are available, which work well for components with elastomeric features like gaskets, seals, and housings. 

PolyJet design guidelines will help you understand capabilities and limitations.

 

Why Choose PolyJet For Your 3D Printing Project?

PolyJet technology offers outstanding detail, surface smoothness and precision, creating  detailed prototypes that convey final-product aesthetics. You can simulate elastomers and flexible parts, create prototyping designs for overmoulding and liquid silicone rubber moulding and manufacture really complex part geometries. We also offer a number of secondary services such as painting, post machining and measurement and inspection, to further enhance the finish of your 3D-printed project design. 

PolyJet material data sheets can be found in our Material Comparison Guide

 

How Does PolyJet Work?

The PolyJet process begins by spraying small droplets of liquid photopolymers in layers that are instantly UV cured. Voxels (three-dimensional pixels) are strategically placed during the build, which allow for the combination of both flexible and rigid photopolymers know as digital materials. Each voxel has a vertical thickness equal to the layer thickness of 30 microns. The fine layers of digital materials accumulate on the build platform to create accurate 3D-printed parts.

Each PolyJet part is completely coated in support material during the build, which ultimately is removed by hand using a pressurized water stream and a chemical solution bath. No post-curing is required after the manufacturing process.

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  • 1 to 50+ parts
  • Shipped in 1 to 7 working days
Common Applications
  • simulating elastomers and flexible parts
  • prototyping designs for overmoulding and liquid silicone rubber moulding
  • combining two-tone colours and multiple materials into a single part
  • manufacturing complex part geometries
 

 

Watch: Polyjet: What is it used for?

Polyjet is an advanced 3D printing process that allows us to simulate elastomers and flexible parts and create prototyping designs for overmoulding and liquid silicone rubber moulding.

We can combine two-tone colours and multiple materials into a single part and manufacture the most complex part geometries.

Find out more about this exciting technology in our new video


 

 

Watch: Which Technology for Your Plastic Part?

Here at Protolabs we offer a variety of cutting-edge technologies to produce precision-engineered parts from a range of plastics, designed to suit your needs. From Multi Jet Fusion (MJF) to Selective Laser Sintering (SLS) to Stereolithography, we can create the parts you need quickly and precisely.

Plus, with our technical support team on call, we can talk to you about your designs and help you to choose the ideal production solution for your needs, and show you just what we can do to help you reach your creative vision.

Want to find out more about our cutting-edge plastic technologies? Watch this video.


Design Guidelines: Polyjet   

NORMAL RESOLUTION 490mm x 390mm x 200mm (Stratasys OBJET 500 Connex 3)
NORMAL RESOLUTION 297mm x 210mm x 200mm (Keyence AGILISTA 3200W)

Layer Thickness

NORMAL RESOLUTION 30 microns

 

Minimum Feature Size

NORMAL RESOLUTION 0.3mm

For well-designed parts, tolerances of ±0.1mm plus ±0.001mm/mm can typically be achieved. Note that tolerances may change depending on part geometry.

Minimum free-standing wall or feature is 0.80mm. Holes, channels, and slots less than 0.80mm in diameter/width will not form; maximum length-to-width aspect ratio is 4:1.

PolyJet provides the ability to choose a desired hardness or combine material properties into a single build, which makes it ideal for prototyping overmolding parts. Shore A hardnesses of 30A, 40A, 50A, 60A, 70A, 85A, 95A, and rigid are available in these colors:

VIEW MATERIALS >

We use multiple additive machines that offer large build sizes, accurate parts, and quick production times. Our PolyJet equipment consists of Stratasys OBJET 500 Connex 3 and Keyence AGILISTA 3200W machines.


Benefits of Polyjet

  • Provides one of the best surface finishes of any additive process
  • Good for producing complex parts
  • Can support complex geometries with multiple materials and colours
  • High Accuracy

What is Polyjet used for?

Polyjet is a great option for anyone needing fast, flexible, accurate prototyping parts, with the ability to incorporate multiple hardness levels and/or material colours, in a single build.

Good for use in a wide variety of industries including the automotive industry, for things such as rubber seals and semi-rigid gaskets. The medical industry for protoyping orthopaedic implants and dental prostheses for fit-testing. Also good for flexible straps and covers on athletic equipment.

Polyjet Design Considerations

  • Unsupported walls and features can be as small as 0.8mm, but if they are to be used in a functional fashion or for load-bearing, they should be at least 1.0mm across. Height of these features depends partly on the material and part geometry. Very tall freestanding walls and bosses should be avoided as they can be damaged when support is removed.
  • It is difficult to remove support materials on holes, slots, and channels that are much smaller than 0.75mm across. In reality, features this narrow may not form properly.
  • Weep holes and land-locked shapes are ok if holes are large enough to allow for rinsing of support material. However, unless there is good reason, it is suggested to leave them closed. It's likely you won't notice the trapped support material.
  • Prototypes for overmoulded parts or those with integral gasket material, should be designed with zero clearance of up to 0.05mm interference fit. Leaving any kind of gap can result in components coming apart in your hands. 
  • Digital Photopolymers have soft touch and flexible features, they also have improved grip, impact resistance and two-toned colouring aesthetics.
  • 3D Printed silicone has high temperature and weather resistance. Allows for the possibility of very-thin walls and elastic models. It also comes in different hardnesses and thin parts can be easily bent thanks to their good elasticity.

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