Multi Jet Fusion
Multi Jet Fusion is a powder-based 3D printing technology. This type of additive manufacturing is particularly suitable for creating functional or end-use parts and small series components due to its high part quality, high throughput, and low unit costs.Multi Jet Fusion enables the production of durable and resistant polyamide 12, polyamide 12 W, elastic TPU and flexible polyamide 11 in short lead times, even for higher quantities.
Brief Information
Technology
Multi Jet Fusion
Build Chamber
min. 10 mm
max. 380 mm
Production Time
from 4 working days
Accuracy
depending on material
The Multi Jet Fusion Printing Process
Multi Jet Fusion is a powder bed-based additive manufacturing technique. In the first stage of this process, a closed layer of powder is applied. This raw material is typically white and consists of polyamide particles with an average size of approximately 60 micrometers.
Application of a closed powder layer – HP Multi Jet Fusion (Source: 3D Printing with HP Multi Jet Fusion Technology – Functionality and Potential)
During the second stage, a black liquid or ink, known as the “fusing agent,” is used to print the areas designated for fusion onto the powder layer. Integrated infrared heating sources on the print head warm the powder bed immediately after the application of the ink. The black areas printed with the fusing agent absorb more energy than the unprinted white areas, causing them to melt and solidify once the heat source is removed.
Fusing Agent – HP Multi Jet Fusion (Source: 3D printing with HP Multi Jet Fusion technology – how it works and its potential).
Another substance, called the “detailing agent,” is employed for isolation purposes. It is applied around the regions printed with the fusing agent. The detailing agent acts as a thermal insulator at the transitional areas, which is crucial for achieving optimal detail resolution.
Image: HP; HP’s white paper on Multi Jet Fusion technology.
The performance capabilities of this system are remarkable, as it can deliver 300 million fluid droplets per second with a precision of 21 micrometers. Despite the complexity of this technology, it offers significant advantages:
- Isotropy: Unlike many other additive manufacturing processes, 3D-printed objects created using Multi Jet Fusion are predominantly isotropic. This means that the mechanical properties of a part are, for the most part, independent of its orientation.
- Speed: In a typical 12-hour print run, we can produce between 180 and 200 components. This makes Multi Jet Fusion one of the most efficient additive manufacturing processes, averaging just 3 to 4 minutes per part.
- Resolution: Due to the small droplets, the Multi Jet Fusion system boasts a resolution of 1,200 dpi along the X-Y axis. Furthermore, the rapid printing process enables the economical use of even smaller layer heights, down to 80 micrometers.
- Density: The “agents” uniformly cover the entire model area and fuse consistently. After fusing, the components achieve nearly 100% material density, with only the surface exhibiting slight porosity. Surface sealing through vapor smoothing allows the components to be fully sealed and suitable for use in gas- and liquid-carrying systems.
Process Chain
Industrial additive manufacturing involves numerous process steps before and after the actual 3D printing. Each of these steps is optimized for quality: you can find an overview of this on the page “Certified Additive Manufacturing at 3Faktur.”
We maintain one of the most extensive process chains for this technology throughout Europe. In addition to the facilities mentioned here, we work with numerous other components in the periphery, such as industrial air conditioning and ventilation technology, measuring instruments, and proprietary IT systems for production control and automation of business and production processes.
Employees processing CAD data
1 / Data verification: CAD data is individually checked for producibility and, if necessary, improvement options are discussed with our customers.
Nesting of components during data preparation
2 / Data preparation: Each component is individually oriented and all production steps and parameters are defined. After this process, the “nesting” takes place, during which the components are nested into each other. This results in the so-called print job, which is transferred to the machine.
Multi Jet Fusion 3D printer during inspection
3 / 3D printing: The actual 3D printing takes 12 to 16 hours, depending on the material and the equipment. We work with four Multi Jet Fusion 3D printers (2 x 4210 and 2 x 5210) from HP.
Building units during cooling
4 / Cooling phase: After printing is complete, the build units are removed from the printer and slowly cooled from > 150 °C to 22 °C for 48 to 72 hours. This reduces component damage (e.g. shrinkage, warpage, surface damage).
Automatic unpacking station with separated components
5 / Unpacking: The build area is completely filled with powder after printing. The components must be removed from this so-called “powder cake”. This process step is now mainly automated.
State-of-the-art blasting booth with automation technology
6 / Cleaning: Due to the high temperatures, residual powder has “melted” onto the components. This is removed mechanically and largely automatically by glass bead blasting (two blast cabinets from MHG: 1 x Cleaning SMG 160; 1 x Shot Peening SMG 50).
State-of-the-art, AI-based automatic component recognition and sorting
7 / Sorting: Several dozen to thousands of components are produced in each print job. For quality reasons, it makes sense to mix different parts in the process. Allocating these to the subsequent steps or jobs after printing is a very labor-intensive process, which we solve with the help of state-of-the-art AI-based automation technology (automatic component recognition, sorting and packaging system from AM-Flow).
Components in the dye basin
8 / [Optional] Dyeing: For black components, dip dyeing of the components is performed.
Component in the processing drum during shot peening
9 / [Optional] Shot peening: All black components undergo a second blasting pass with a different blasting medium, during which the surface is compacted (“shot peening” or “compaction blasting”). The process is semi-automated in a blast cabinet optimized for this purpose.
Equipment for chemical smoothing
10 / [Optional] Vapor Smoothing: If desired, chemical smoothing can be performed to obtain a smooth, pore-free surface. (AMT SF 50 plant for vapor smoothing).
Test report after quality control
11 / Quality control: Quality control is one of our most complex operations. In addition to the actual components, we also produce and evaluate production samples for each cycle. This enables us to intervene at an early stage, for example if there are signs of consumable wear, and ensures the highest possible level of replicability.
Automatic packaging and labeling with the AM Bagging system
12 / Packaging & Shipping: After the release of the components, the final allocation, packaging and shipping take place. In the meantime, we have also been able to automate the allocation and part of the packaging with the “AM Bagging” system.
Applications
Multi Jet Fusion can be used to additively manufacture stable, durable plastic components. Applications span all industries, e.g.
Housings
Enclosures that can withstand mechanical, thermal and chemical stress can be manufactured quickly and efficiently.
Structural elements
Components from the “inner workings” of machines and systems can also be manufactured with very complex geometries.
Weight or topology-optimized components
The ability to print undercuts or grid structures makes Multi Jet Fusion ideal for lightweight construction.
Data courtesy of GOT/3Faktur
Fixtures
Stable materials with infinite geometric complexity: Multi Jet Fusion is ideal for building fixtures.
Data courtesy of Invent Medical
Orthotics
TPU in particular is now widely used in the production of patient-specific orthoses.
Data courtesy of 3Faktur
Gas- and liquid-carrying components
Finishing with Vapor Smoothing allows the creation of completely sealed components.
Finishing
Unfinished
Gray components used for non-visible components.
Black coloring & Shot peening
Colored and surface finished components used mainly for visible components.
More info about dyeing
More information about Shot Peening
Vapor Smoothing (chemical smoothing)
Black colored, chemically smoothed and sealed surfaces for numerous applications.
More info on Vapor Smoothing