PolyJet 3D printing produces highly detailed, smooth parts that look close to production straight off the printer. It can combine rigid and rubber-like materials in a single part, which makes it a strong choice for appearance models, overmold prototypes, and small, finely detailed parts. Our shop is in Coopersville, Michigan, just west of Grand Rapids, and we ship parts nationwide.
How PolyJet 3D Printing Works
PolyJet was developed by Objet Geometries, which merged with Stratasys in 2012. It works much like an inkjet document printer, but instead of ink on paper it jets layers of liquid photopolymer onto a build tray.
- Print heads jet tiny droplets of photopolymer in the shape of one layer of the part.
- UV lamps cure each layer immediately as it is printed.
- A gel-like support material is jetted at the same time to hold up overhangs and fine features.
- Different materials can be jetted in the same layer, so one part can combine rigid and rubber-like areas.
- When the part is done, the support material is removed by hand or with water.
When to Choose PolyJet 3D Printing
PolyJet is the right fit when appearance and fine detail matter most:
- Appearance models and photo-ready prototypes
- Small, finely detailed parts and connectors
- Overmold prototypes that combine a rigid body with a rubber-like grip or seal
- Clear parts for lenses, light covers, and fluid flow visualization
- Rubber-like parts in a range of Shore A hardnesses
- Master patterns for RTV silicone molds
- Medical devices, small housings, and packaging prototypes
PolyJet, SLA, or MJF? PolyJet gives the finest detail and can mix rigid and rubber-like materials in one part. SLA is better for large appearance parts and offers more clear and engineering resins. MJF is better for tough functional parts and production quantities. Not sure? Send us the part and we will recommend a process.
PolyJet 3D Printing Capabilities
| Maximum part size | Up to 19.7″ × 15.7″ × 7.9″; larger parts can be printed in sections and bonded |
| Layer thickness | As fine as 0.0006″, typically 0.0006″ to 0.001″ |
| Accuracy | ±0.005″ for the first inch, ±0.0025″ per inch thereafter (see our part accuracy page) |
| Surface finish | Very smooth, with fine layer lines that sand out easily |
| Multi-material | Rigid and rubber-like materials combined in one part, with blended hardness and opacity |
Accuracy depends on part size, geometry, and material. Send us your CAD file and we will give you a realistic estimate for your part.
PolyJet 3D Printing Materials
| Material | Best for |
|---|---|
| Vero (white or black) | Rigid, highly detailed models and prototypes with a smooth, production-like look |
| VeroClear | Transparent parts that simulate acrylic (PMMA): lenses, light covers, and see-through housings |
| Digital ABS (ivory) | Tough, ABS-like parts with higher heat resistance than standard Vero |
| Agilus30 | Rubber-like parts: gaskets, seals, grips, overmolds, and soft-touch surfaces |
Color: Rigid PolyJet parts are printed in white or black. Parts can be painted after printing if you need a specific color.
Blended hardness: PolyJet can mix Agilus30 with rigid Vero during the print to create rubber-like materials at a specific Shore A hardness, from soft and flexible to nearly rigid. That makes it easy to prototype overmolded grips, seals, and soft-touch surfaces in a single part.
VeroClear mechanical properties
| ASTM Method | Property Description | Metric | Imperial |
|---|---|---|---|
| D638M | Tensile Strength | 50-65 MPa | 7,250-9,450 psi |
| D638M | Elongation at Break | 10-25% | 10-25% |
| D638M | Modulus of Elasticity | 2,000-3,000 MPa | 290,000-435,000 psi |
| D790M | Flexural Strength | 75-110 MPa | 11,000-16,000 psi |
| D2240 | Flexural Modulus | 2,200-3,200 MPa | 320,000-465,000 psi |
| D256A | Izod Impact (Notched) | 20-30 J/m | 0.375-0.562 ft-lb/inch |
| D648 | HDT @ 0.46 MPa (66 psi) | 45-50 °C | 113-122 °F |
| D648 | HDT @ 1.81 MPa (264 psi) | 45-50 °C | 113-122 °F |
Download the VeroClear data sheet.
Need production rubber parts in larger quantities? See our MJF TPU rubber option. Compare PolyJet with our other processes on the machine and material comparison guide.
Finishing Options for PolyJet Parts
PolyJet parts have a smooth surface right off the printer. They can be sanded, primed, and painted for presentation models, clear coated for optical clarity, or used as master patterns for RTV silicone molds. See all finishing and post-processing options.
Designing Parts for PolyJet
Our engineering team at DeWys Engineering designs parts for PolyJet regularly. If your part isn’t ready to print yet, our design for additive manufacturing services can help, from design review to full CAD design.
If you would rather design the part yourself, we strongly recommend starting with our PolyJet Part Design Guide. Our engineers built it from years of PolyJet projects as a place to keep the lessons we have learned, and we publish it so anyone designing for PolyJet can benefit.
A few things PolyJet handles well:
- Rigid and rubber-like materials in one part, such as a hard body with an overmolded grip
- Rubber-like areas at a specific Shore A hardness
- Assemblies, living hinges, snap fits, and pin hinges
- Class A surfaces for model making
- No draft required
- Serial numbers and text printed into each part
- Threaded brass inserts glued in after printing
PolyJet Part Examples
Rigid parts
Clear parts
Rubber-like and multi-material parts
PolyJet 3D Printing FAQ
What is PolyJet 3D printing best for?
Highly detailed appearance models, small precise parts, clear parts, and prototypes that combine rigid and rubber-like materials, such as overmolded grips and seals.
How big can PolyJet parts be?
Up to 19.7″ × 15.7″ × 7.9″ in one piece. Larger parts can be printed in sections and bonded, or printed with SLA.
Are PolyJet parts strong enough for functional use?
PolyJet parts are rigid and accurate but more brittle than thermoplastics, so they are best for prototypes, fit checks, and models. For parts that need to take real loads, MJF or FDM are usually a better fit.
Can PolyJet print rubber-like parts?
Yes. Agilus30 is a rubber-like material, and it can be blended with rigid Vero to hit a range of Shore A hardnesses, all in the same part as rigid features.
ISO 9001:2015 Certified Quality
Our quality management system is certified to ISO 9001:2015 and covers engineering, additive manufacturing, post-processing, and inspection, so customer requirements are handled consistently from quote to delivery. Learn more about our ISO 9001:2015 certification.