Many engineers assume "jetting" refers to one technology. It actually covers several distinct approaches — PolyJet-style photopolymer jetting, drop-on-demand systems, and NanoParticle Jetting for metals and ceramics. Each solidifies material differently and serves different jobs, from dental models to jewelry casting patterns.
This guide breaks down how material jetting actually works, layer by layer, plus the limitations worth knowing before you specify it for your next project.
Key Takeaways
- Material jetting deposits droplets of photopolymer, wax, or similar feedstock through printheads and cures them layer by layer.
- Droplet placement, layer thickness, curing, and support strategy determine the final part's accuracy and finish.
- The process suits high-detail prototypes, dental models, jewelry patterns, and design validation work.
- Photopolymer parts aren't automatically suited for durable end-use applications due to strength and heat-resistance limits.
What Is Jet 3D Printing?
Material jetting is an additive manufacturing process that selectively deposits droplets of build material, layer by layer, rather than extruding filament or fusing powder. ISO/ASTM 52900 names photopolymer resin and wax as standard material jetting feedstocks.
Most systems jet photopolymer droplets cured instantly with UV light. Others, like 3D Systems' MultiJet Printing platform, also jet casting wax that solidifies as it cools rather than through light exposure.
Engineers value the process because droplets land with sub-100-micron precision. That yields sharp edges, legible fine text, accurate color, and rigid-plus-flexible materials in a single build. Extrusion and powder-bed processes can't easily match that mix.
How It Differs from Other Processes
Material jetting gets confused with two related terms:
- Binder jetting deposits a liquid binding agent into a powder bed to join particles. The powder is the build material, not the jetted liquid.
- Inkjet printing creates flat, two-dimensional images. It shares the droplet-deposition mechanism but produces no three-dimensional part.
Material jetting deposits the actual build material itself, layer after layer, into a solid object.
Types of Material Jetting Technology
Three variations dominate the market:
- PolyJet-style photopolymer jetting (Stratasys) — UV-cured liquid resin, often multi-material and full-color.
- Drop-on-demand systems — piezo printheads release droplets on command, common in wax and resin platforms like 3D Systems' MJP line.
- NanoParticle Jetting (XJet) — jets metal or ceramic nanoparticle ink alongside soluble support, followed by sintering.
Because layers can run just a few microns thick, material jetting delivers smooth surfaces and tight color control few other processes match.
How Does Material Jetting Work?
Material jetting follows a clear sequence: prepare the file, jet and cure each layer, then remove supports and inspect the part. Most of the quality outcome is locked in before the first droplet lands.
Initiation and File Preparation
Before printing starts, the operator makes several decisions that shape the outcome:
- Orient the part to balance surface quality, support volume, build time, and dimensional accuracy
- Choose layer height (thinner layers raise resolution but slow the build)
- Assign materials and colors so the correct printhead channels fire in each region
- Flag supports for overhangs, cavities, and thin unsupported features
Files still need watertight geometry, correct scale, and wall thickness the machine can reproduce. A 0.3 mm wall may print cleanly on one platform and fail on another, depending on droplet size and material viscosity.
Droplet Deposition
Once the file is ready, printhead nozzles pass across the build area and deposit controlled droplets onto the platform or the previous layer. Drop-on-demand systems release each droplet only when triggered, giving tight control over placement.
A few variables drive consistency here:
- Nozzle condition: clogged or worn nozzles distort droplet size and placement
- Material viscosity: must stay in a narrow range for clean jetting
- Printhead calibration: slight misalignment shows up as banding or dimensional drift
Keep nozzles clean and recalibrate on schedule—jetting quality tracks maintenance as closely as hardware specs.
Curing and Layer Formation
As droplets land, UV lamps (or cooling, on wax-based systems) solidify each layer before the next one prints. Immediate curing is what lets material jetting hold fine features without collapse or bleed into neighboring geometry.
Layer thickness, droplet size, and layer leveling all shape the result. The Stratasys J850 Pro prints horizontal layers as thin as 14 microns and holds dimensional deviation under ±100 microns for parts smaller than 100 mm. Thinner layers cut visible stair-stepping, at the cost of build speed.
Support Material and Complex Geometry
Most material jetting systems jet a second, weaker material with the build material to hold overhangs and cavities that would otherwise sag mid-print. On 3D Systems MJP platforms, that support is often a wax that melts away without manual scraping. The ProJet MJP 2500 Plus, for example, uses melt-away supports that leave parts usable without extra cleaning or polishing.
Other systems dissolve support in a water bath or remove it by hand. Plan support access early: deep internal channels or fully enclosed cavities can trap material that is hard to reach later.
Output, Inspection, and Post-Processing
The part that comes off the platform is largely or fully cured, but it usually still needs support removal, washing, and possibly surface finishing before it's ready for use.
For precision components, inspection earns its keep here:
- Check dimensions against the original CAD file
- Inspect surfaces for defects or incomplete curing
- Fit-test against mating parts or assemblies
Accuracy, repeatability, and shrinkage vary by printer and material—skip universal figures. The MJP 300W Plus, for instance, is rated at ±0.0508 mm per 25.4 mm on a single printed part. Verify that class of spec against your own printer and material pair before you lock tolerances.
Where Material Jetting Is Used
Material jetting is used most often in product development—concept models, form-and-fit checks, design reviews, and marketing prototypes that need to look and feel like the finished part. It also supports low-volume specialty production when a photopolymer or wax matches the job.
Precision-Focused Applications
- Dental models and guides: Stratasys reports that 3DIEMME increased surgical guide output from 8 to nearly 50 per day on a J5 DentaJet PolyJet system, without adding staff.
- Jewelry and casting patterns: MJP 300W Plus systems print 100% wax patterns with VisiJet materials for direct lost-wax casting, with no separate pattern-making step.
- Medical and anatomical models: Patient-specific models from imaging data help surgeons plan complex procedures before the OR.
- Educational and consumer prototypes: Full-color, multi-material builds let teams judge look and feel early.
Visual and planning models are not cleared clinical devices; materials and validation requirements differ.
Industrial and Engineering Uses
Manufacturing teams also use material jetting to validate complex assemblies, internal channels, ergonomic shapes, seals, and multi-material interfaces before committing to tooling.
One automotive supplier prototyped a full dashboard on a multi-material PolyJet system—rigid and soft-touch textures in one build—and cut turnaround by half.
Suitability still depends on matching the material to real operating conditions. Heat, chemical exposure, and mechanical load vary by application.
Selection Checklist
Before specifying material jetting for a project, check:
- Required accuracy and surface finish
- Color, transparency, or multi-material needs
- Flexibility and expected mechanical loading
- Heat and chemical exposure in the end-use environment
- Support-removal access for the part's geometry
- Inspection requirements and expected part quantity
- Total cost, including materials and post-processing
Conclusion
Material jetting turns a digital model into thin slices, then guides printheads to deposit droplets exactly where the design calls for them. Each layer cures solid before the next begins. Repeat that sequence hundreds of times, remove the support material, and you get the fine detail and smooth finish the process is known for.
Choosing between PolyJet-style photopolymer jetting, drop-on-demand wax systems, and NanoParticle Jetting means matching material properties, accuracy, and post-processing to your application. The smallest quoted layer thickness alone is not the deciding factor.
If you're weighing printers, materials, software, or workflow support for dental, jewelry, medical, or industrial work, CAD BLU's team can walk through the tradeoffs. We can recommend a setup that fits your production goals.
Frequently Asked Questions
How much does a PolyJet 3D printer cost?
Pricing varies widely by build size, printhead setup, material channels, color options, software, and service terms. Contact CAD BLU for current model-specific pricing rather than relying on a general figure.
What is the most profitable thing to 3D print?
Profitability depends on demand, part complexity, material and labor costs, and compliance requirements. High-detail prototypes, dental and medical models, and jewelry casting patterns are common candidates, but no single product wins in every market.
What materials are used in material jetting 3D printing?
Common feedstocks include photopolymers (rigid, flexible, transparent, and full-color), wax-based casting materials, and dedicated support materials. Available options depend entirely on the printer platform you're using.
Is material jetting more accurate than other 3D printing methods?
Material jetting can achieve very fine detail and smooth surfaces, but real-world accuracy depends on the machine, material, part geometry, and calibration. No single process ranks highest in every setup.
Does material jetting require support structures?
Most material jetting systems jet a separate support material to hold overhangs and complex geometry during the build. Support removal method and access should factor into your design decisions upfront.
What are the disadvantages of material jetting?
Main limitations include equipment and material costs, support-related post-processing time, and photopolymers that can age or turn brittle over time. Heat and chemical sensitivity also mean you should match materials to the intended application.
