{"id":75058,"date":"2025-11-28T18:36:06","date_gmt":"2025-11-28T10:36:06","guid":{"rendered":"https:\/\/xometry.asia\/?p=75058"},"modified":"2025-11-28T18:36:11","modified_gmt":"2025-11-28T10:36:11","slug":"3d-printing-polyjet-design-tips","status":"publish","type":"post","link":"https:\/\/staging-wp.xometry.asia\/en\/3d-printing-polyjet-design-tips\/","title":{"rendered":"PolyJet 3D Printing: 8 Key Design Tips for Better Prints"},"content":{"rendered":"\n<p>Hi, I\u2019m Niko Mroncz, Head of Sales Engineering at Xometry. I\u2019ve worked across a wide range of 3D printing technologies since 2010, and PolyJet remains unmatched when it comes to combining ultra-fine detail, smooth surfaces, and multi-material flexibility. But with that level of precision comes the need for equally precise design.<\/p>\n\n\n\n<figure class=\"wp-block-image\"><img decoding=\"async\" src=\"https:\/\/xometry.pro\/wp-content\/uploads\/2025\/07\/polyjet-3d-prints.png\" alt=\"\"\/><\/figure>\n\n\n\n<p><a href=\"https:\/\/xometry.asia\/en\/3d-printing\/\">PolyJet<\/a>\u00a0is a photopolymer-based 3D printing technology that jets and cures tiny droplets of resin layer by layer using UV light. It excels at producing highly detailed, accurate parts with sharp edges, smooth finishes, and complex geometries\u2014including full-color and multi-material assemblies in a single build.<\/p>\n\n\n\n<p>This makes PolyJet ideal for visual prototypes, ergonomic models, medical guides, and fit-check assemblies where tactile realism or fine texturing matters.<\/p>\n\n\n\n<h4 class=\"wp-block-heading\">Nikolaus Mroncz<\/h4>\n\n\n\n<p>Head of Sales Engineering<\/p>\n\n\n\n<p>But PolyJet can be tricky\u2014it requires deliberate design choices to avoid defects. Parts are sensitive to wall thickness, support removal, and trapped resin. For great-looking, functional prints, it\u2019s all about smart choices\u2014like escape holes, proper wall thickness, and enough clearance for assemblies. Here are the tips I always keep in mind to get clean results and parts that work like they should.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\" id=\"h-1-set-wall-thickness-and-feature-size-for-reliable-prints\"><strong>1. Set Wall Thickness and Feature Size for Reliable Prints<\/strong><\/h2>\n\n\n\n<p>Thin walls warp or crack during support removal, especially if unsupported. Similarly, undersized features often fail or print distorted, reducing function and appearance.<\/p>\n\n\n\n<p><strong>Rule of Thumb:<\/strong><\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>Minimum wall thickness:&nbsp;<strong>1 mm&nbsp;<\/strong>(supported),&nbsp;<strong>1.5 mm<\/strong>&nbsp;(unsupported); increase to&nbsp;<strong>1.5\u20132 mm<\/strong>&nbsp;in load-bearing or flex-prone areas to prevent cracking<\/li>\n\n\n\n<li>Minimum feature size:&nbsp;<strong>0.5 mm<\/strong><\/li>\n<\/ul>\n\n\n\n<figure class=\"wp-block-image\"><img decoding=\"async\" src=\"https:\/\/xometry.pro\/wp-content\/uploads\/2023\/12\/Maximum-Wall-Thickness-Icon-1-1024x1024.png\" alt=\"Maximum Wall Thickness Icon\" class=\"wp-image-103972\"\/><\/figure>\n\n\n\n<h2 class=\"wp-block-heading\" id=\"h-2-leave-enough-clearance-for-pre-assembled-and-moving-parts\"><strong>2. Leave Enough Clearance for Pre-Assembled and Moving Parts<\/strong><\/h2>\n\n\n\n<p>PolyJet can print complex assemblies in one piece\u2014but without proper clearance, parts may fuse during printing. This is especially important for ball joints, hinges, and interlocking features. Use generous spacing unless the design is strictly static or lightly loaded, and always test with prototypes before final production.<\/p>\n\n\n\n<p><strong>Rule of Thumb:<\/strong><\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>Minimum clearance between assembled parts:&nbsp;<strong>0.5 mm<\/strong><\/li>\n\n\n\n<li>Clearance for moving parts:&nbsp;<strong>0.5 mm<\/strong><\/li>\n\n\n\n<li>Add&nbsp;<strong>alignment features<\/strong>&nbsp;(e.g. dowel pins, slots) for precise fit<\/li>\n\n\n\n<li>Use<strong>&nbsp;snap-fit features<\/strong>&nbsp;only when you can maintain \u00b10.1 mm accuracy\u2014otherwise, opt for post-assembly fasteners<\/li>\n<\/ul>\n\n\n\n<figure class=\"wp-block-image\"><img decoding=\"async\" src=\"https:\/\/xometry.pro\/wp-content\/uploads\/2023\/12\/clearance-between-moving-parts-_clearance-between-moving-parts-1024x1024.png\" alt=\"Clearance between moving parts\" class=\"wp-image-104020\"\/><\/figure>\n\n\n\n<h2 class=\"wp-block-heading\" id=\"3-split-large-assemblies-into-joinable-sections\"><strong>3. Split Large Assemblies into Joinable Sections<\/strong><\/h2>\n\n\n\n<p>PolyJet\u2019s maximum build size is&nbsp;<strong>490 \u00d7 391 \u00d7 200 mm<\/strong>. Split larger parts for separate printing and post-assembly, and use mechanical features\u2014like dovetails, puzzle cuts, or interlocking tabs\u2014to improve alignment and joint strength.<\/p>\n\n\n\n<p>Plan for assembly early: allow clearance for bonding, and place splits in low-stress, hidden zones to preserve strength and finish. Use CAD sectioning tools to create puzzle joints and align with dowel pins or slots.<\/p>\n\n\n\n<p><strong>Rule of Thumb:<\/strong><\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>Assembly clearance:<strong>&nbsp;0.5 mm<\/strong>&nbsp;between mating parts to avoid fusion<\/li>\n\n\n\n<li>Add&nbsp;<strong>alignment features<\/strong>&nbsp;(e.g. dowels, slots, tabs) to aid positioning<\/li>\n\n\n\n<li>Use&nbsp;<strong>joining strategies<\/strong>&nbsp;like dovetail joints, puzzle cuts, or tongue-and-groove<\/li>\n\n\n\n<li>Choose bonding or friction fit based on part size, load, and accuracy<\/li>\n<\/ul>\n\n\n\n<h2 class=\"wp-block-heading\" id=\"4-include-escape-holes-to-prevent-trapped-resin\"><strong>4. Include Escape Holes to Prevent Trapped Resin<\/strong><\/h2>\n\n\n\n<p>Trapped resin causes defects and waste. To avoid this, design escape holes that allow trapped resin to drain during post-processing. For long or deep sections, add access points or removable sacrificial parts to ensure clean interiors.<\/p>\n\n\n\n<p><strong>Rule of Thumb:<\/strong><\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>Add escape holes for enclosed volumes deeper than&nbsp;<strong>50 mm<\/strong><\/li>\n\n\n\n<li>Use hole diameters of<strong>&nbsp;2\u20134 mm<\/strong>&nbsp;for effective drainage<\/li>\n\n\n\n<li>For functional pin holes, use a minimum diameter of&nbsp;<strong>2 mm<\/strong><\/li>\n\n\n\n<li>For non-functional features, avoid holes smaller than&nbsp;<strong>0.5 mm<\/strong><\/li>\n\n\n\n<li>Add removable sacrificial rods or tabs in deep cavities to ease cleaning<\/li>\n<\/ul>\n\n\n\n<h2 class=\"wp-block-heading\" id=\"5-add-fillets-to-reinforce-thin-or-sharp-features\"><strong>5. Add Fillets to Reinforce Thin or Sharp Features<\/strong><\/h2>\n\n\n\n<p>Sharp internal corners and thin junctions are stress concentrators that can lead to cracks or delamination\u2014especially during support removal or handling. Adding fillets reduces these weak points, distributes stress more evenly, and improves structural integrity.<\/p>\n\n\n\n<p>This is especially important for thin-walled parts or intersecting geometries.<\/p>\n\n\n\n<p><strong>Rule of Thumb:<\/strong><\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>Use a fillet radius of<strong>&nbsp;0.5\u20131.5 mm<\/strong>&nbsp;depending on part size<\/li>\n\n\n\n<li>Round all internal corners with&nbsp;<strong>\u22650.5 mm<\/strong>&nbsp;fillets to prevent stress cracks<\/li>\n\n\n\n<li>Add support structures for overhanging fillets to avoid sagging during printing<\/li>\n<\/ul>\n\n\n\n<figure class=\"wp-block-image\"><img decoding=\"async\" src=\"https:\/\/xometry.pro\/wp-content\/uploads\/2023\/12\/support-structure-icon-3-1024x1024.png\" alt=\"Support structure icon\" class=\"wp-image-103996\"\/><\/figure>\n\n\n\n<h2 class=\"wp-block-heading\" id=\"6-size-embossed-and-engraved-details-for-readability\"><strong>6. Size Embossed and Engraved Details for Readability<\/strong><\/h2>\n\n\n\n<p>PolyJet allows for fine surface details like logos, text, and patterns\u2014but without proper sizing, they may print poorly or disappear during post-processing.<\/p>\n\n\n\n<p>Sanding or support removal can blur or erase shallow features, so always size them with enough depth or height for visibility.<\/p>\n\n\n\n<p><strong>Rule of Thumb:<\/strong><\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>Use&nbsp;<strong>sans-serif fonts<\/strong>&nbsp;for best legibility<\/li>\n\n\n\n<li>Minimum line thickness:&nbsp;<strong>0.5 mm<\/strong><\/li>\n\n\n\n<li>Engraved text depth:&nbsp;<strong>0.5 mm<\/strong><\/li>\n\n\n\n<li>Embossed text height:&nbsp;<strong>0.5 mm<\/strong>&nbsp;(with minimum thickness of 0.8 mm)<\/li>\n<\/ul>\n\n\n\n<figure class=\"wp-block-image\"><img decoding=\"async\" src=\"https:\/\/xometry.pro\/wp-content\/uploads\/2023\/12\/Embossing-Height-Icon-1024x1024.png\" alt=\"Embossing Height Icon\" class=\"wp-image-104056\"\/><\/figure>\n\n\n\n<h2 class=\"wp-block-heading\" id=\"7-use-hollowing-strategies-to-reduce-material-usage\"><strong>7. Use Hollowing Strategies to Reduce Material Usage<\/strong><\/h2>\n\n\n\n<p>Hollow parts to reduce weight and material use\u2014especially for large aesthetic parts or visual prototypes\u2014while keeping strength and appearance. Hollow only non-load-bearing functional parts. Keep solid areas around fasteners and stress zones.<\/p>\n\n\n\n<p>Use ribs, internal supports, or lattices to reinforce hollow sections. Always include drainage holes to let uncured resin escape, and position them at the lowest point of the part during printing.<\/p>\n\n\n\n<p><strong>Rule of Thumb:<\/strong><\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>Add drainage holes (<strong>2\u20134 mm<\/strong>) to release trapped resin<\/li>\n\n\n\n<li>Place&nbsp;<strong>drainage holes<\/strong>&nbsp;at the lowest point on the build<\/li>\n\n\n\n<li>Use&nbsp;<strong>ribs or lattices&nbsp;<\/strong>to support large internal cavities<\/li>\n<\/ul>\n\n\n\n<h2 class=\"wp-block-heading\" id=\"8-support-overhangs-and-freefloating-features-strategically\"><strong>8. Support Overhangs and Free-Floating Features Strategically<\/strong><\/h2>\n\n\n\n<p>PolyJet prints with a gel-like, water-soluble support material that washes away after printing\u2014but unsupported features can still sag or deform. Overhangs steeper than 45\u00b0 typically need support, as do floating elements and horizontal bridges.<\/p>\n\n\n\n<p>Minimize the need for support by optimizing part orientation and designing self-supporting features where possible. Limit support contact to \u22641 mm\u00b2 per point to reduce surface blemishes.<\/p>\n\n\n\n<p><strong>Rule of Thumb:<\/strong><\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li><strong>Support overhangs &gt;45\u00b0<\/strong>&nbsp;and floating features<\/li>\n\n\n\n<li>Use&nbsp;<strong>minimal contact points<\/strong>&nbsp;(e.g. teardrop shapes) to reduce marks<\/li>\n\n\n\n<li>Orient flat surfaces horizontally and tilt overhangs &lt;45\u00b0 toward the base to minimize support needs<\/li>\n\n\n\n<li>Use denser supports for heavy or complex features; lower density for small details<\/li>\n<\/ul>\n\n\n\n<figure class=\"wp-block-image\"><img decoding=\"async\" src=\"https:\/\/xometry.pro\/wp-content\/uploads\/2023\/12\/Unsupported-Overhang-Icon-1024x1024.png\" alt=\"\" class=\"wp-image-116180\"\/><\/figure>\n\n\n\n<h2 class=\"wp-block-heading\" id=\"polyjet-3d-printing-specifications-reference-guide\"><strong>PolyJet 3D Printing Specifications Reference Guide<\/strong><\/h2>\n\n\n\n<p>Use the values below as a reference when preparing parts for printing\u2014going beyond them can lead to deformation, fused features, or lost detail.<\/p>\n\n\n\n<figure class=\"wp-block-table\"><table class=\"has-fixed-layout\"><thead><tr><th>Feature<\/th><th>Value<\/th><\/tr><\/thead><tbody><tr><td>Maximum build size<\/td><td>490 \u00d7 390 \u00d7 200 mm<\/td><\/tr><tr><td>Minimum feature thickness<\/td><td>0.5 mm<\/td><\/tr><tr><td>Suggested minimum wall thickness<\/td><td>1 mm<\/td><\/tr><tr><td>Layer thickness<\/td><td>16\u201330&nbsp;\u00b5m, depending on the material<\/td><\/tr><tr><td>General tolerance<\/td><td>\u00b10.1 mm for the first 25 mm is typical, plus \u00b10.05 mm for each additional 25 mm. Tolerances may change depending on part geometry.<\/td><\/tr><\/tbody><\/table><\/figure>\n\n\n\n<h2 class=\"wp-block-heading\" id=\"get-your-highquality-polyjet-3dprinted-parts-at-xometry\"><strong>Get Your High-Quality PolyJet 3D-printed Parts at Xometry<\/strong><\/h2>\n\n\n\n<p>Mastering PolyJet design unlocks the ability to create smooth, highly detailed, multi-material parts with exceptional precision. By applying the tips in this guide\u2014controlling wall thickness, sizing features correctly, managing supports, and planning for assemblies\u2014you\u2019ll reduce print errors and produce consistent, high-quality results.<\/p>\n\n\n\n<p>Ready to bring your designs to life with unmatched accuracy and surface quality? Partner with Xometry for expert guidance and fast, reliable\u00a0<a href=\"https:\/\/xometry.asia\/en\/3d-printing\/\" target=\"_blank\" rel=\"noreferrer noopener\">PolyJet 3D printing<\/a>\u00a0tailored to your exact needs.<\/p>\n","protected":false},"excerpt":{"rendered":"<p>Hi, I\u2019m Niko Mroncz, Head of Sales Engineering at Xometry. I\u2019ve worked across a wide range of 3D printing technologies since 2010, and PolyJet remains unmatched when it comes to combining ultra-fine detail, smooth surfaces, and multi-material flexibility. But with that level of precision comes the need for equally precise design. PolyJet\u00a0is a photopolymer-based 3D [&hellip;]<\/p>\n","protected":false},"author":37,"featured_media":75057,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"footnotes":""},"categories":[30,39],"tags":[],"class_list":["post-75058","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-blog","category-3d-printing"],"acf":[],"publishpress_future_action":{"enabled":false,"date":"2026-09-13 21:59:19","action":"change-status","newStatus":"draft","terms":[],"taxonomy":"category","extraData":[]},"publishpress_future_workflow_manual_trigger":{"enabledWorkflows":[]},"_links":{"self":[{"href":"https:\/\/staging-wp.xometry.asia\/en\/wp-json\/wp\/v2\/posts\/75058","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/staging-wp.xometry.asia\/en\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/staging-wp.xometry.asia\/en\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/staging-wp.xometry.asia\/en\/wp-json\/wp\/v2\/users\/37"}],"replies":[{"embeddable":true,"href":"https:\/\/staging-wp.xometry.asia\/en\/wp-json\/wp\/v2\/comments?post=75058"}],"version-history":[{"count":0,"href":"https:\/\/staging-wp.xometry.asia\/en\/wp-json\/wp\/v2\/posts\/75058\/revisions"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/staging-wp.xometry.asia\/en\/wp-json\/wp\/v2\/media\/75057"}],"wp:attachment":[{"href":"https:\/\/staging-wp.xometry.asia\/en\/wp-json\/wp\/v2\/media?parent=75058"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/staging-wp.xometry.asia\/en\/wp-json\/wp\/v2\/categories?post=75058"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/staging-wp.xometry.asia\/en\/wp-json\/wp\/v2\/tags?post=75058"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}