1. Introduction
The demand for high-performance, scalable manufacturing solutions has never been greater. Companies across industries are looking for ways to reduce costs, shorten production cycles, and create more complex, functional parts. HP’s Multi Jet Fusion (MJF) 3D printing technology is revolutionizing the way manufacturers produce end-use parts, offering unmatched speed, precision, and material efficiency.
At the core of MJF’s success are its advanced materials, engineered for strength, durability, and cost-effectiveness. With options ranging from rigid nylons to flexible elastomers, HP’s material portfolio enables everything from low-volume production to full-scale manufacturing. This white paper explores the unique benefits of HP 3D printing materials and how they are transforming modern manufacturing.
2. What Makes HP Jet Fusion Materials Unique?
HP Jet Fusion materials stand out due to their mechanical strength, high reusability, and ability to scale production efficiently. Unlike traditional 3D printing methods, which often result in anisotropic properties (where strength varies based on part orientation), HP’s MJF technology produces fully dense, isotropic parts with performance comparable to injection molding.
Key Advantages of HP Jet Fusion Materials
- Superior Print Speed and Throughput
HP’s voxel-level control allows for precise and simultaneous layer fusion, significantly reducing print times. Unlike selective laser sintering (SLS), which relies on point-by-point laser scanning, HP’s thermal print process completes layers in a fraction of the time. This makes MJF one of the fastest 3D printing technologies for batch production. - Minimal Post-Processing for Streamlined Production
Unlike FDM (which requires support removal and smoothing) or SLA (which requires curing), HP Jet Fusion parts require minimal post-processing. Parts emerge with high surface quality and detail, often eliminating the need for additional finishing and reducing overall labor costs. - Material Reusability for Cost Efficiency
HP’s High Reusability (HR) materials, such as PA 12 and Polypropylene (PP), can be reused at rates of 80–90%, minimizing waste and lowering cost per part. This makes MJF a cost-effective option for companies looking to scale production. - Designed for Mass Production
HP’s technology enables batch production and on-demand manufacturing with consistent repeatability. Whether producing 100 or 10,000 parts, MJF materials maintain uniform strength, accuracy, and finish.
3. Overview of HP Jet Fusion Materials
HP offers a diverse range of materials tailored to specific performance needs, from high-strength nylons to flexible elastomers.
Core HP Jet Fusion Materials:
- PA 12 (Nylon 12) – Strong, durable, and chemically resistant. Ideal for automotive, aerospace, and medical components.
- PA 12 Glass Beads (PA 12 GB) – Reinforced with 40% glass for high rigidity and heat resistance. Used in brackets, jigs, and structural supports.
- PA 11 – More flexible and impact-resistant than PA 12. Commonly used in prosthetics, sporting goods, and snap-fit assemblies.
- Polypropylene (PP) – Lightweight, chemically resistant, and weldable. Used in fluid-handling systems, medical devices, and automotive applications.
- TPU (Thermoplastic Polyurethane) – Flexible, abrasion-resistant, and durable. Ideal for seals, gaskets, and protective gear.
- TPA (Thermoplastic Polyamide) – Soft, lightweight elastomer with excellent energy return for footwear, grips, and impact-resistant parts.
Each material offers unique mechanical properties tailored to different applications, ensuring optimized performance for every industry.
4. How Material Selection Impacts Performance
Choosing the right material is crucial for ensuring durability, functionality, and efficiency in production. HP Jet Fusion offers a range of materials designed to meet specific mechanical, thermal, and chemical resistance needs.
Key Performance Factors:
- Strength & Rigidity – PA 12 GB is ideal for structural parts and industrial tooling that must hold their shape under stress.
- Flexibility & Impact Resistance – PA 11 and TPU offer high ductility, making them perfect for snap-fit designs, prosthetics, and protective gear.
- Chemical & Moisture Resistance – Polypropylene (PP) withstands harsh chemicals and is water-resistant, making it suitable for medical and fluid-handling applications.
- Heat Resistance – PA 12 GB maintains dimensional stability at higher temperatures, making it useful for automotive and industrial components.
Material selection should align with real-world application needs, balancing cost, durability, and performance.
5. HP Jet Fusion vs. Traditional Manufacturing
While injection molding and CNC machining remain dominant for large-scale production, HP Jet Fusion offers key advantages for low-to-medium production runs, rapid prototyping, and complex part geometries.
Comparison: HP Jet Fusion vs. Injection Molding
| Feature | HP Jet Fusion | Injection Molding |
| Setup Time | Hours to days | Weeks to months |
| Tooling Costs | None | High |
| Best for | Low-to-medium production, custom parts | High-volume mass production |
| Design Flexibility | Complex geometries, lightweight structures | Limited by tooling |
| Lead Time | Rapid iteration, on-demand | Long production cycle |
| Material Waste | High reusability (up to 90%) | Significant material waste |
For applications that require fast turnaround, design flexibility, and cost-efficient small-batch production, HP Jet Fusion is the better choice.
Where HP Jet Fusion Excels:
- Custom, complex parts that would be costly or impossible with traditional methods
- Rapid product development without the delays of tooling
- Cost-efficient, small-to-medium production runs
- Sustainable production with high material reusability
6. Industries Benefiting from HP Jet Fusion Materials
HP Jet Fusion materials are widely adopted across industries that require high-strength, cost-effective, and scalable production solutions. By eliminating tooling costs and enabling on-demand manufacturing, HP’s technology is reshaping multiple sectors.
Aerospace & Automotive
Lightweight, high-performance parts are essential for fuel efficiency and structural integrity. PA 12 and PA 12 GB provide the strength and heat resistance needed for brackets, enclosures, and under-the-hood components. The ability to iterate quickly and produce complex geometries gives engineers more design flexibility.
Medical & Healthcare
Customization and biocompatibility are key in prosthetics, surgical tools, and medical enclosures. PA 11 and Polypropylene (PP) are favored for their flexibility, sterilization compatibility, and chemical resistance. These materials allow for patient-specific solutions without the high costs of traditional manufacturing.
Consumer Goods
Brands are leveraging TPA and TPU to produce custom footwear, protective gear, and flexible products. These materials offer a balance of durability and elasticity, making them ideal for wearables, impact-resistant goods, and sporting equipment.
Industrial & Robotics
Manufacturers rely on PA 12 GB for jigs, fixtures, and factory tooling due to its stiffness and dimensional stability. In robotics, PA 12 and PA 11 enable lightweight, strong components like robotic arms, grippers, and casings, enhancing automation efficiency.
7. Key Considerations for Adopting HP Jet Fusion
1. Define Your Application Needs
Before selecting a material, determine your part’s requirements: Does it need to be strong, flexible, heat-resistant, or chemically resistant?
2. Leverage Design for Additive Manufacturing (DfAM)
HP Jet Fusion allows for lighter, more complex designs that reduce material usage and consolidate assemblies. Optimizing designs for strength and efficiency can lower costs and improve performance.
3. Partner with Experts
Choosing the right manufacturing partner ensures proper material selection, optimized designs, and scalable production. Working with an experienced provider like RapidMade helps maximize the benefits of HP Jet Fusion.
8. Why Choose RapidMade for HP Jet Fusion?
HP Jet Fusion technology offers exceptional speed, repeatability, and material efficiency—but expertise in design and production is critical to fully unlock its potential.
Why RapidMade?
- Deep expertise in HP Jet Fusion and material selection
- Support from prototyping to full-scale production
- Fast turnaround, cost-effective solutions, and on-demand manufacturing
Learn how HP Jet Fusion 3D printing can transform your manufacturing.
Visit www.RapidMade.com to get started.
