But here's the problem: two PolyJet materials can look nearly identical on a build tray and perform in completely different ways once you pick the part up. One flexes like rubber. Another cracks under light pressure. Heat resistance, transparency, biocompatibility, and how well a part holds up after months of use all depend on which photopolymer you choose, not just which printer you own.
This guide walks through the main PolyJet material families, connects their properties to real-world applications, and gives you a practical framework for choosing and handling materials with confidence.
Key Takeaways
- PolyJet jets liquid photopolymers, UV-cures them instantly, and prints support material with the model
- Material families span rigid opaques, rubber-like elastomers, transparent optical resins, and digital composites
- "ABS-like" and "polypropylene-like" labels mean simulated behavior—not true thermoplastic performance
- Choose by flexibility, strength, heat, chemicals, and service life—not appearance alone
How PolyJet Materials Work
PolyJet is a material jetting process. Print heads move across the build tray and deposit microscopic droplets of liquid photopolymer, layer by layer. UV lamps mounted next to the print heads cure each layer almost instantly, so the part solidifies as it's built rather than in a separate post-cure step, according to Stratasys' technology overview.
Most builds also need support material. Overhangs, cavities, thin walls, and complex internal geometries can't hold their shape on their own while printing. PolyJet printers jet a separate support material alongside the build material, then remove it afterward through water jetting, soaking, or manual cleaning, depending on the system.
Multi-material printing
Multiple print heads make multi-material printing possible. Because each head can jet a different photopolymer, some printer systems can:
- Combine rigid and rubber-like resins in a single build
- Blend colors from a base palette to match a target hue
- Create "digital materials" with properties between two base resins, such as a part that transitions from firm to soft
The number of materials, colors, and blend combinations available depends on the specific printer and its validated material system. Not every combination works on every machine, so checking compatibility before designing a multi-material part saves rework later.
What Materials Are Used in PolyJet 3D Printing?
PolyJet printers offer a wide range of photopolymer families, each suited to different jobs. Here's how the major categories break down.
Rigid opaque photopolymers
Rigid opaque materials are the workhorse of PolyJet printing. They're used for general prototypes, housings, appearance models, design reviews, and any part that needs a solid visual presentation without seeing through it.
Stratasys' Vero family is a common example, available in blue, white, black, gray, cyan, magenta, and yellow, with white grades formulated for extra opacity and brightness. Reported mechanical values include:
- Tensile strength: 50-65 MPa
- Flexural modulus: 2,200-3,200 MPa
- Heat deflection temperature: 45-50°C
These numbers matter for anything beyond a purely visual model. A rigid opaque part looks production-ready, but its heat tolerance sits well below most engineering thermoplastics, so treat it as an appearance and light-functional material rather than a load-bearing one.
Transparent and translucent photopolymers
Clear and translucent photopolymers are used for lenses, fluid-flow mockups, light pipes, windows, and any model where you need to see inside or through a part. VeroClear is a common transparent option that simulates PMMA/acrylic and can be blended with other resins to shift opacity or hardness.
Straight off the printer, transparent parts have a slightly frosted look from the layer surface. Genuine optical clarity usually requires polishing, lacquering, or photo bleaching after printing.
Some materials go further. VeroUltraClear reaches 86% light transmission at 6mm thickness, according to Stratasys' VeroUltraClear data sheet. That makes it suited for eyewear, lighting components, and clear housings where you need to watch fluid or mechanisms move.
Rubber-like and elastomeric materials
Rubber-like photopolymers cover soft-touch grips, seals, gaskets, buttons, overmold simulations, and flexible prototypes that need to bend or compress. Agilus30 is a well-known example, sold in clear, black, and white variants.
Reported data for this family includes:
- Shore A hardness: 30-40 (varies by variant)
- Tensile strength: 2.1-3.1 MPa
- Elongation at break: 185-270%
Not every rubber-like grade behaves the same way. Hardness ranges shift between variants and printer systems, so pull current manufacturer data sheets before assuming a specific Shore value will match your grip or seal design.
Digital and blended materials
Some PolyJet printers can jet up to six base materials at once and blend them to create hybrid properties. This lets a single build combine:
- A rigid body with a softer, rubber-like grip zone
- A gradual transition from hard to soft across one part
- Custom colors matched against thousands of validated Pantone references
A common example is a handheld tool mockup: firm plastic for the housing, a soft zone where a hand grips it, with no assembly step required.
The catch is that blended digital materials inherit properties from their base resins. A soft-to-hard transition zone won't necessarily match either base material's data sheet exactly.
Simulated engineering materials
ABS-like, polypropylene-like, high-temperature, and impact-oriented photopolymers are built to stand in for production thermoplastics during prototyping. Digital ABS Plus, for example, reports:
- Tensile strength: 55-60 MPa
- Heat deflection temperature: 58-68°C, rising to 82-95°C after thermal post-treatment
- Notched Izod impact: 90-115 J/m
Polypropylene-like resins such as Durus and Rigur trade some rigidity for elongation and impact resistance, closer to how PP behaves. High-temperature materials report HDT up to 63-67°C, climbing higher with post-processing.
One catch matters most: these photopolymers simulate ABS or PP mechanically, thermally, and visually. They are not the same plastics. A snap-fit that survives testing in simulated ABS won't necessarily survive identical stress in production ABS.
Biocompatible and specialty materials
Some PolyJet systems offer materials cleared for specific dental, medical, or skin-contact uses, such as anatomical models, surgical guides, dental try-ins, and drilling guides. Biological evaluation for these materials commonly references EN ISO 10993-1:2018 and includes cytotoxicity, genotoxicity, and USP Plastic Class VI testing.
Before making any safety claim, confirm:
- The exact intended contact duration the material is cleared for
- Regulatory documentation specific to that material and printer combination
- Whether steam, gamma, or EtO sterilization is approved for that grade
- Post-processing conditions required to preserve the biocompatibility claim
Skipping any of these steps can void the material's validated status, even if the part looks identical to a properly processed one.
How to Choose the Right PolyJet Material
Choose a PolyJet material by matching its properties to what the part must do—not by chasing a single "best" grade.
Match the material to the part's purpose
Start by asking what the part actually needs to do. Is it:
- An appearance model for a design review
- A fit-check prototype for assembly testing
- A flexible component simulating a soft-touch feature
- A functional prototype under real mechanical load
- A dental or medical model
- A casting pattern
- A limited-use end part
A grade picked for visual realism may fail under repeated flexing, heat, outdoor exposure, or solvents. Use the real job—not just appearance—as the first filter.
Compare the most important material properties
Once you know the part's purpose, compare the properties that matter using current technical data sheets, not marketing copy:
- Stiffness plus tensile and flexural behavior
- Impact resistance and elongation at break
- Shore hardness (for flexible grades)
- Heat deflection temperature
- Transparency and surface finish
- Dimensional stability and aging behavior
Print orientation, wall thickness, geometry, print mode, support placement, UV exposure, and post-processing all change real-world performance. A data-sheet value from a standard test bar will not automatically transfer to a thin-walled or oddly oriented part.
Consider appearance and multi-material requirements
Sometimes color, translucency, and finish matter more than raw mechanical performance. Full-color capability, precise color matching, matte versus glossy finish, and soft-touch zones can be the deciding factor for consumer-facing models.
| Build type | Best for | Tradeoff |
|---|---|---|
| Single-material | Simple parts, lowest cost | Limited appearance/property range |
| Multi-material | Assemblies needing different properties in one build | More setup complexity |
| Digitally blended | Color matching, graduated hardness | Higher cost, more finishing steps |
Multi-material and blended builds take more setup and support planning, but they reduce post-print assembly.
Account for heat, chemicals, and environment
Heat, sunlight, moisture, solvents, oils, and cleaning agents all affect photopolymer parts over time—and not always predictably.
A 2024 study in the Journal of the Mechanical Behavior of Biomedical Materials found that support-removal treatment and aging changed elongation, modulus, and tensile strength in both rigid and flexible PolyJet materials over 30 to 180 days. Glycerol treatment made flexible material stiffer, while aging tended to restore some elongation.
Heat- and chemical-resistance claims apply to a specific material, printer, curing method, and test condition—not to PolyJet as a category.
If the part will sit in a hot warehouse or get wiped with solvent daily, test a representative sample under those conditions before you commit.
Get expert input before committing
Choosing among photopolymer families—plus orientation, support strategy, and finishing—is hard to do in isolation. CAD BLU helps teams evaluate printer, material, software, support, and workflow options before they lock in an approach. OEM-trained, certified technicians can map the combination that fits the part, budget, and production goal.
Where PolyJet Materials Are Used
The same fine-detail capability shows up across a range of industries, though the specific material and workflow shift with each one.
Product design and engineering
Design teams lean on PolyJet for:
- Appearance models and color-coded prototypes
- Ergonomic studies and soft-touch simulations
- Fit and assembly checks before tooling
Automotive, consumer product, industrial, and aerospace teams use these builds to validate a concept before committing to tooling.
A single multi-material build can show a rigid housing next to a soft-touch button zone. Reviewers get something that looks and feels close to final without cutting a mold.
Dental, medical, and healthcare
Specialty materials support dental models, anatomical models, surgical planning aids, and other healthcare workflows. Draw a clear line, though: a visualization model used to plan surgery is not a regulated, patient-contact device.
Anatomical models and surgical simulation tools help residents practice procedures before working on patients. That is planning and education use, not an implanted or patient-contact device. Always confirm whether a material's clearance covers the specific contact scenario you have in mind.
Jewelry, casting, and education
PolyJet's fine detail suits presentation models, classroom demonstrations, and training aids. Casting workflows exist across additive manufacturing, but whether a given PolyJet material is validated for a specific casting process depends on that material's data sheet and the foundry's requirements.
Education and cultural heritage projects also use PolyJet to replicate detailed artifacts for study and display. Fine surface detail translates well to accurate reproductions.
Small-batch and limited-use parts
PolyJet materials can support low-volume production, custom fixtures, and limited-use components where fine detail and quick turnaround matter more than long-term durability. Think one-off jigs, short-run presentation pieces, or a fixture used for a handful of production cycles.
For parts that face high temperatures, repeated impact, chemical exposure, or years of service, choose technologies and materials built for that demand. Do not stretch a photopolymer beyond its tested limits.
PolyJet Material Workflow, Supports, and Care
Choosing the right material is half the job. How you store, print, and finish it determines whether that material performs as expected.
Preparing and storing materials
Follow manufacturer guidance for handling cartridges or containers. Good practice includes:
- Keeping materials sealed in their original, UV-proof container until use
- Storing indoors, away from direct sunlight, at room temperature
- Avoiding contamination between different material types
- Checking shelf life or lot dates and use-by dates before printing
For technical, dental, or medical workflows, traceability matters. Record the material name, lot information where available, printer used, print mode, and post-processing conditions for every build. Those records help if a part later needs validation or comes under question.
Removing supports and finishing parts
Support removal typically happens through water-jet cleaning, manual removal, soaking, or another manufacturer-approved method, depending on the printer system. Aggressive removal—especially on thin walls or delicate details—can damage the features you need most.
Support contact also affects surface texture and gloss. Surfaces that touched support material during printing often come out matte or slightly textured compared to surfaces that didn't. If appearance matters, plan part orientation and support placement before printing, not after.
Validating and maintaining performance
After printing, check:
- Dimensions and fit
- Surface quality
- Flexibility
- Visible defects
Then test representative parts under actual or simulated operating conditions. Do not assume data sheet numbers will hold for your specific geometry.
As production scales beyond occasional prototyping, professional support becomes more relevant. CAD BLU supports installation, workflow optimization, repair, and technical service for businesses moving from one-off prototypes toward repeatable production workflows.
Frequently Asked Questions
What is PolyJet 3D printing?
PolyJet is an inkjet-style material jetting process that deposits and UV-cures photopolymer droplets layer by layer. Compatible systems can produce complex, detailed, multicolor, and multi-material parts in a single build.
What materials do PolyJet printers use?
PolyJet systems use rigid opaque, transparent, rubber-like, digitally blended, simulated engineering, high-temperature, and specialty biocompatible photopolymers. Availability varies by printer model and manufacturer.
What are the key differences between SLA and PolyJet 3D printing?
Both use UV-cured photopolymers, but PolyJet jets droplets through print heads layer by layer, so one build can combine materials and colors. SLA cures liquid resin in a vat with a laser and is typically a single-material process with a different material range and cost structure.
How accurate is PolyJet 3D printing?
PolyJet is known for fine detail and smooth surfaces, but actual dimensional accuracy depends on the printer, material, print mode, part geometry, orientation, calibration, and post-processing. Check current technical data sheets for any specific tolerance claim.
Which 3D printer is best for multi-material printing?
PolyJet systems are built for multi-material and multicolor parts in a single build. Choose a model based on the material combinations, build size, accuracy, software, and production volume you need, and compare current manufacturer specifications.
What is the best modeling software for 3D printing?
The best software depends on whether you're creating mechanical CAD, organic forms, dental models, jewelry designs, or print-preparation files. Confirm file compatibility and workflow integration with your selected printer before choosing.
