PolyJet 3D printing, developed by Stratasys, is one of the most advanced polymer additive manufacturing technologies available today. Known for its exceptional precision, fine surface finish and multi-material capabilities, PolyJet allows users to create realistic prototypes, intricate models and functional components with unmatched detail.
Compared to other available technologies, it is only platform that offers true multi-material printing for unparalleled realism. It is a revolutionary multi-material jetting process that uses photopolymers for 3D printing. It offers the widest range of materials including full colour rigid, opaque, flexible, transparent and vivid materials as well as specialised materials for dental and medical applications. For the user, PolyJet enables you to produce smooth, detailed prototypes that convey final-product aesthetics as well as accurate moulds, jigs and fixtures. All of these can be fabricated in complex geometries with intricate details, various surface finishes in an almost infinite array of colours, making PolyJet the ultimate tool for designers.
How PolyJet 3D Printing Works
PolyJet printing operates in a manner similar to an inkjet printer — but rather than depositing ink, it jets layers of liquid photopolymer onto a build tray. These layers are instantly cured using ultraviolet (UV) light, creating a solid part. The process repeats layer by layer at a resolution as fine as 14 microns, producing models with smooth surfaces, sharp edges and complex geometries.
Support material, typically a gel-like substance, is automatically printed to enable overhangs and delicate features, then easily removed after printing by water jet or hand rinsing.
- The printing block moves along the X-Y axis in order to maximize the printing area coverage and reach the entire build platform
- The Build Platform moves in z direction layer by layer in order to build the entire geometry
- Drops of liquid Photopolymer are deposited on the building tray by the Printing Block, layer by layer
- Exposure to UV light, initiates a very fast polymerization reaction turning the liquid photopolymer into a fully cured ready to use 3D model
- PolyJet technology is based on Photopolymer resins, UV light and motion working simultaneously in order to produce precise full color and functional 3D models like no other technology
Advantages of PolyJet Technology
- Ultra-high resolution: Achieves some of the finest layer thicknesses in polymer additive manufacturing, enabling smooth surfaces and intricate details.
- Multi-material printing: PolyJet can combine different materials in a single build — from rigid to flexible, opaque to transparent — allowing simulation of real-world products.
- Full-colour capability: Systems like the Stratasys J850 Prime can print in over 500,000 colour combinations for realistic prototypes and anatomical models.
- Fast turnaround: Rapid layer curing enables high throughput and quick iteration during product development.
- Excellent surface finish: Minimal post-processing is needed, ideal for models requiring aesthetic appeal.
Applications of PolyJet Printing
PolyJet’s ability to produce visually accurate and multi-material models makes it ideal for:
- Art and education – Bring complex visual concepts to life with full-colour, detailed 3D models
- Product design and prototyping – Create realistic prototypes with accurate colours, textures and material properties
- Medical and dental modelling – Produce lifelike anatomical models for surgical planning, education and patient communication.
- Consumer products – Evaluate ergonomics and aesthetics in early-stage product development
- Engineering validation – Test form, fit and function before committing to tooling or production.
PolyJet Materials
Stratasys offer a wide range of materials to support PolyJet 3D printing. These include rigid, flexible, transparent and opaque polymers that enable almost any colour and texture possibility needed to create realistic models. The material range can be divided up into:
- Basic Materials – Ideal for prototyping and proof of concept
- Design Materials – A range of opaque to transparent coloured polymers with tailored mechanical properties
- Functional Materials – Higher performance polymers for testing prototype functionality
- Medical Materials – Biocompatible materials for medical applications
- Dental Materials – Biocompatible materials for dental applications
- Support Materials – Includes soluble, water soluble and gel-like materials to support overhangs and complicated geometries
PolyJet in the Additive Manufacturing Landscape
In the broader context of polymer 3D printing, Stratasys PolyJet technology occupies a unique position between Fused Deposition Modelling (FDM), Stereolithography (SLA) and P3-DLP (Programmable Photopolymerization) technologies.
- Compared to FDM, PolyJet delivers vastly superior resolution, surface quality and the ability to combine multiple materials and colours within a single print. However, FDM remains the better choice for functional, load-bearing parts thanks to its use of engineering thermoplastics such as ABS, ASA and Nylon.
- Compared to SLA, PolyJet offers faster build speeds for complex or multi-material parts and less post-processing. SLA can produce slightly stronger, more heat-resistant parts, but lacks PolyJet’s multi-material and colour capabilities.
- Compared to P3-DLP, PolyJet excels in surface finish, colour, and material versatility, making it ideal for visual models and prototypes. P3-DLP, by contrast, is optimised for production-grade performance, offering higher mechanical strength, chemical resistance and thermal stability. P3 systems such as the Stratasys Origin One and Origin Two use a precisely controlled light engine and closed-loop process monitoring to deliver consistent, high-quality parts suitable for end-use manufacturing.
In essence, PolyJet is the go-to choice for aesthetic realism and design validation, while P3-DLP bridges the gap between prototyping and true production. Together, these technologies complement each other within the Stratasys ecosystem — enabling customers to progress seamlessly from concept modelling through to functional part production.
Conclusion
Stratasys PolyJet 3D printing stands out as a precision-driven, design-focused technology that brings ideas to life with exceptional realism. Its combination of speed, material versatility and surface quality makes it invaluable for industries such as product design, healthcare, education and engineering. While not intended for end-use production, its ability to replicate the look, feel and function of final products continues to make it an essential tool in modern manufacturing workflows.
