Multi-Jet Fusion (MJF) in3D printingThis is a relatively new technology, but in just a few years, MJF began moving toward industrialization. Today, MJF is widely used by manufacturers as a reliable parts manufacturing technology for a variety of products, including automotive parts, factory tools, orthopedic devices and consumer products.
The latest MJF 3D printer series is the Jet Fusion 5400 series. First of all, we introduce the HP Jet Fusion 5420W printer. In addition to printing ordinary dark gray nylon materials, it can also print white nylon materials. This new white material solution is sought after by the medical, automotive and consumer goods industries, providing post-processing opportunities for more vibrant colors and better light refraction.
MJF has also been used in footwear, not only collaborating with French sports brand Decathlon, but also collaborating with luxury brand Botter to launch 3D printed concept sneakers (see photo above). The shoes are printed using a flexible TPU material, which is also the material chosen by cycling equipment manufacturer Posedla for its 3D printed Joyseat bicycle saddle.
△3D printing concept shoes from Reebok/Botter and Decathlon, using Multi Jet Fusion 3D printing technology
Technical principles of multi-jet fusion
△HP Jet Fusion 5420W solution
Multi Jet Fusion is a 3D printing technology introduced to the market by HP in 2016, building on decades of HP research in the areas of inkjet printing, disposable materials, precision machines to low cost, materials science and imaging. Simply put, the technology uses liquid adhesive to fuse powdered polymer materials layer by layer and gets its name from the use of multiple inkjet heads. Note that HP’s Multi Jet Fusion should not be confused with the Metal Jet printing process used in its metal printers; the two are very similar and Metal Jet uses metal powder instead of plastic. This article focuses on multi-jet fusion technology, using only plastic.
△The MJF process is divided into five stages
Although MJF does not fit neatly into one of the seven categories of 3D printing technologies defined by the International Organization for Standardization (ISO), it is a type of binder jetting. All binder jet 3D printing technologies use an inkjet print head to spray liquid material onto a layer of powder material. Traditionally, plastic or polymer binder jetting is a “cold” technology, but HP has introduced heat into the printing process, significantly changing the process.
In the multijet fusion printing process, the printer deposits a layer of material powder on the print bed. An inkjet head then passes over the powder, depositing fusing and refining agents into a digital model of the desired part. The infrared heater also moves across the print. Wherever you add a blending agent, the underlying layers will “melt” together, while areas exposed to the detailing agent will not be completely blended and areas to which the agent has not been applied will be always in powder. The unmelted powder supports the molten material, thereby eliminating the support. To complete the printing process, the entire powder bed and the printed parts it contains are moved to a separate processing station. During this step, most of the unmelted loose powder is vacuumed up and can be reused.
△Thanks to HP 3D printing, Triple August Race Engineering can produce lightweight but strong parts faster
Multi-jet fusion is a versatile technology that has found applications across many industries, helping manufacturers in all aspects of the development process, from prototyping, to creating working prototypes for field testing, to manufacturing of final parts.
Application areas of multi-jet fusion
Some industries that have seen success with MJF include:
●Car
MJF 3D printing helps automotive and automotive manufacturers reduce component production costs while improving operational efficiency. A Spanish automotive parts supplier (Continental Automotive Spain SA) uses MJF printing to develop pneumatic fasteners to reduce processing time for new parts. At Jaguar Land Rover, automotive engineers use HP Multi Jet Fusion to develop next-generation protective equipment for factory workers; General Motors’ new 15,000 square foot Additive Industrialization Center is integrating HP MJF machines into its fleet of 3D printers to produce prototype parts. , tools, accessories and end-use parts.
△Invent Medical’s 3D printed Raptor mask is made with an HP Multi Jet Fusion 3D printer
●Medical technology
The benefits of 3D printing and digital manufacturing have continued to grow during the pandemic, filling supply chain gaps and accelerating one-piece design. HP and its global network of partners and customers have 3D printed more than 5 million parts to meet urgent needs and create new ecosystems for local manufacturing.
In the medical and dental sectors, there is an explosion of 3D printing applications and mass personalized products. SmileDirectClub in Nashville, Tennessee has 60 HP Multi Jet Fusion printers working around the clock to create custom dental molds; HP Jet Fusion 3D printers are also changing the orthotics industry and enabling the production of customizable medical prosthetics. Invent Medical uses HP White PA12 Custom Manufacture; orthotics and prosthetics that offer new possibilities for post-impression coloring for pediatric care.
△ Eyewear is one of the fastest growing consumer product categories, manufactured using HP Multi Jet Fusion 3D printing.
● Consumer goods
Many types of consumer products require the production of low-volume, complex-shaped parts. PepsiCo, one of the world’s leading food and beverage companies, encountered a problem while trying to design a small face mask to cover its beverage cans, tying into the Black Panther film. PepsiCo tested various 3D printing technologies to create the fine details and deep black colors of the superhero masks. Ultimately, MJF stands out for its high production speed and sustainability; HP also works with customers in the sporting goods and eyewear industries, and with Multi Jet Fusion, Oakley is shortening the development phase of its eyewear, as well as other sports equipment. . Smith’s custom 3D-printed frame for the I/O MAG Imprint ski goggles was named one of the best inventions of 2022 by Time magazine.
Advantages and disadvantages of multi-jet fusion
△Rendering of the HP MJF machine as a manufacturing solution
advantage
●Fast printing speed
●Mass production cycle
● Precise printing, presenting exquisite details
●Personal printing costs are low
●Free design, no support required
●Powder recycling reduces waste
●Possibility of coloring parts in post-processing
●High quality surface finish
● Constant mechanical properties
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●Expensive initial investment in printer
●All exclusive materials
●Unable to produce certain curved and hollow geometries
●The final product is gray without dye (except when printing with the new Jet Fusion 5420W solution)
HP MJF machine range
△HP 3D Jet Fusion 4200 Series 3D Printer
HP primarily offers two sets of HP Multi Jet Fusion 3D printers and supporting equipment: the HP 3D Jet Fusion 4200 launched in 2016 (with some upgrades since) and the HP Jet Fusion 5200 series launched in 2019 and the 5420W 2023 launched in 2019; , almost identical to the 5200 series, except that the printing system is dedicated to white parts only. HP has other MJF machines that were primarily used for prototyping and are now retired.
4200 series
The 4200 Series is HP’s first part intended for low- and high-volume production, making it ideal for industrial prototyping and final part production. Touted as an easy-to-use solution that can be tailored to your business, the 4200 uses HP’s proprietary smelting and refining agents and materials, with an external tank that can extract reused materials from the processing station so they can can be replaced by different materials.
An automated material mixing and loading system streamlines workflow and reduces labor. The machine includes a closed unpacking and material collection system and a cooling module so that the finished print bed can be removed and replaced with a new one to maximize reduction in downtime.
△ HP Jet Fusion 5200 Complete Series (Source: HP)
Daguang focuses on providing solutions such as precision CNC machining services (3-axis, 4-axis, 5-axis machining), CNC milling, 3D printing and rapid prototyping services.
