Multi Jet Fusion Polypropylene For Chemical-Resistant, Weldable Parts

Polypropylene 3D printed part example
Genuine Polypropylene
Chemical Resistant and Weldable
MJF material

Polypropylene overview

Polypropylene (PP) is one of the most common injection-moulded plastics, and HP Multi Jet Fusion 3D printing makes parts in genuine PP rather than a PP-like substitute. HP 3D High Reusability PP stands up to many chemicals, absorbs very little water and is light enough to float, and printed parts can be welded to moulded PP parts. That lets you test prototypes in the same plastic as the production part, and print end-use parts without tooling. Choose it for fluid reservoirs, piping, tanks and containers, automotive parts and orthotics.

How polypropylene is manufactured

Polypropylene is manufactured using HP Multi Jet Fusion (MJF) on the HP Jet Fusion 5200, an industrial powder-bed process that applies fusing and detailing agents with 1200 dpi precision and fuses each full layer with infrared energy. Parts build without support structures or tooling.

Build volume
380 × 284 × 380 mm
Lead time
4-8 business days
Layer height
0.08 mm
Forge Labs Steam

Know before you manufacture in polypropylene.

Every polypropylene quote is prepared by an engineer with a manufacturability review, so warp-prone flat sections and tight fits are fixed before the part prints.

Every polypropylene quote is prepared by an engineer with a manufacturability review, so warp-prone flat sections and tight fits are fixed before the part prints.

Industry applications

Industry applications for Polypropylene

Polypropylene lets teams print in the polymer their production parts are moulded in. Product developers test fit, snap action, chemical exposure and welding on prototypes that behave like the moulded part, and manufacturers print end-use reservoirs, fittings, housings and orthoses without tooling or minimum order quantities.

It sits at the top of the HP Multi Jet Fusion range for chemical resistance, low moisture absorption and light weight, which suits piping, fluid systems and containers that sit in water, coolant, cleaning chemicals or dilute acids and bases.

Printed parts weld to injection-moulded PP with standard plastic welding processes, so printed caps, ports and fittings join moulded parts.

Choose it over HP MJF PA12 when chemical resistance, moisture, weight or welding matter more than stiffness, heat resistance and tight tolerances. Choose Tough 1500 Resin, a PP-like SLA resin, when a prototype needs a smooth surface, finer detail and far more stretch, and the real polymer is not required.

All industries
MJF polypropylene fluid reservoir with a welded seam being fitted in a car engine bay

Automotive

Fluid Reservoirs & Welded Assemblies

MJF polypropylene suits automotive fluid reservoirs, fluid and HVAC system parts and interior parts, and prototypes print in the polymer the production part is moulded in. One plastics assembly specialist printed fluid reservoir parts in MJF polypropylene and hot-plate welded them on prototype tooling: the first functional assembly took six days instead of seven weeks, the weld reached parent-material strength in burst testing and the assembly sealed hermetically in leak testing.

  • Fluid reservoirs and tanks
  • Interior and HVAC parts
  • Welded prototype assemblies
Explore automotive
MJF polypropylene manifold plumbed into a water treatment skid

Clean Tech

Coolant, Water & Chemical-Contact Parts

Equipment builders use MJF polypropylene for manifolds, pipe fittings, tanks and covers that carry water, coolant or process chemicals, where chemical resistance and low moisture absorption count for more than stiffness. Internal channels and integrated fittings print in one part without supports.

  • Manifolds and pipe fittings
  • Tanks and containers
  • Fluid-system housings and covers
Explore clean tech
MJF polypropylene orthosis with ventilation cut-outs on a clinic bench

Medical & Healthcare

Orthoses & Skin-Contact Device Parts

Orthotic and device makers use MJF polypropylene for braces, orthoses and device parts that touch intact skin. Printed parts have been tested to ISO 10993 for intact-skin devices, and low density keeps worn parts light.

  • Orthoses and braces
  • Skin-contact device parts
  • Patient-specific wearables
Explore medical devices
MJF polypropylene snap-fit container prototype on a design bench

Industrial Design

Moulded-PP Prototypes & Snap-Fit Housings

Product teams use MJF polypropylene to prototype housings, caps, clips and containers that will be injection moulded in PP, so fit, snap action, chemical exposure and welding are proven in the production polymer before the mould is cut. Pilot runs and limited launches print with no tooling.

  • Injection-moulding prototypes
  • Snap-fit housings and caps
  • Consumer product pilot runs
Explore industrial design
Performance data

Technical performance for Polypropylene

Values from HP's mechanical properties white paper for HP 3D High Reusability PP on the Jet Fusion 5200 Series, with powder data from HP's materials guide, tested to the standard listed with each property.

Mechanical performance

Mechanical properties

Read this group as a balance of stiffness and give. Tensile modulus shows how firmly a part resists bending: polypropylene is less stiff than PA12, so clips and thin walls deflect with less force, and load-bearing brackets need thicker sections than the same design in PA12. Tensile strength and stiffness are the same in XY and Z, so a part resists static load the same way whichever way it is built.

Elongation at break is higher in XY than in Z, so lay flexing features such as clips and latches in the XY plane. Notched impact strength shows how the material handles a sharp notch, so radius the roots of clips and bosses on parts that will be knocked.

PropertyValue
Tensile Strength (XY / Z)ASTM D638 Type I
29 / 29 MPa
Tensile Modulus (XY / Z)ASTM D638 Type I
1600 / 1600 MPa
Elongation at Yield (XY / Z)ASTM D638 Type I
9.5 / 9.5 %
Elongation at Break (XY / Z)ASTM D638 Type I
20 / 14 %
Izod Impact Strength, Notched 3.2 mm (XY / Z)ASTM D256 Method A
3.5 / 3.0 kJ/m²

Material makeup

Physical properties

Low density is the signature of polypropylene: parts weigh less than the same part in PA12 and are lighter than water, which keeps worn, handheld and moving parts light.

Powder values describe the HP 3D High Reusability PP feedstock. HP also publishes the melt flow index of the powder, which helps compare it with the moulding grade when printed parts are welded to moulded PP.

PropertyValue
Part DensityASTM D792
0.87 g/cm³
Powder Particle SizeASTM D3451
62 µm
Powder Bulk DensityASTM D1895
0.34 g/cm³
Melt Flow Index, Powder (230 °C / 2.16 kg, approx.)ASTM D1238
8 g/10 min

Heat performance

Thermal properties

Heat deflection temperature shows how warm a loaded part can run before it bends. Polypropylene holds its shape under light load well above room temperature, but its deflection temperature drops sharply under higher load, so size loaded parts that run warm from the 1.82 MPa value.

PropertyValue
HDT @ 0.45 MPa (XY / Z)ASTM D648
100 / 100 °C
HDT @ 1.82 MPa (XY / Z)ASTM D648
60 / 60 °C
Powder Melting Point (DSC)ASTM D3418
138 °C

Compatibility data

Chemical properties

HP judges chemical resistance by mechanical property retention, dimensional stability and weight change after immersion, and publishes one overall result across the four chemical classes it tested, not a rating per class or per chemical.

HP names no individual fluids, so treat the result as screening guidance and confirm resistance with application-specific testing in the actual fluid, concentration and temperature before production release, especially for fuels and aromatic or chlorinated solvents.

ChemicalHP immersion testHP result
Acids, bases, organic solvents and aqueous solutions
HP immersion test7 and 30 days
HP resultExcellent overall

Medical readiness

Biocompatibility and compliance profile

Each status comes from HP's regulatory summary for HP 3D High Reusability PP. A third-party laboratory tested parts printed on the Jet Fusion 5200/5210 from 80% reused powder with HP's agents, then sand blasted, soaked in isopropanol for 30 minutes and rinsed in deionized water, to ISO 10993-5, -10 and -11 and the USP pyrogen test, and HP expects similar parts to suit FDA and ISO 10993 guidance for intact-skin devices; each device maker tests its own device.

HP tested printed parts for RoHS substances, PAHs, phthalates, bisphenol A and soluble heavy metals under the ASTM F963 toy standard, and declares REACH registration and no intentionally added GADSL substances. HP states that no HP 3D material is approved for food contact, and it publishes no UL 94 rating for this grade.

StandardStatus
ISO 10993-5 (Cytotoxicity)Test article extract met the requirements; third-party laboratory testing of parts printed on the Jet Fusion 5200/5210 from 80% reused powder with HP fusing and detailing agents, sand blasted, soaked 30 minutes in isopropanol and rinsed in deionized water
HP tested
ISO 10993-10 (Irritation and sensitization)Not a sensitizer in the guinea pig test and met the intracutaneous injection requirements; parts printed on the Jet Fusion 5200/5210 from 80% reused powder, sand blasted, soaked 30 minutes in isopropanol and rinsed in deionized water
HP tested
ISO 10993-11 (Acute systemic toxicity)No mortality or evidence of systemic toxicity; parts printed on the Jet Fusion 5200/5210 from 80% reused powder, sand blasted, soaked 30 minutes in isopropanol and rinsed in deionized water
HP tested
USP <151> Pyrogen testMet the requirements for the absence of pyrogens; parts printed on the Jet Fusion 5200/5210 from 80% reused powder, sand blasted, soaked 30 minutes in isopropanol and rinsed in deionized water
HP tested
FDA Intact Skin Surface Devices guidanceHP expects similar parts made under recommended conditions to suit FDA and ISO 10993 guidance for intact skin surface devices; each customer tests its own device
HP statement
RoHS Directive 2011/65/EU (EU 2015/863)Printed parts tested to IEC 62321; RoHS heavy metals, bromine and chlorine not detected
HP tested
EU REACHREACH registrations completed by HP and/or its partner; no SVHC intentionally added
HP declaration
PAHs in printed partsNo listed polycyclic aromatic hydrocarbons detected above 4 ppb (GC/MS)
HP tested
ASTM F963-17 soluble heavy metals (toys)No soluble heavy metals detected in parts printed from fresh powder on the Jet Fusion 5200; regulated phthalates (CPSIA Section 108) and bisphenol A not detected; chemical composition testing only
HP tested
GADSL automotive declarable substancesGADSL substances not intentionally added; material data entered in IMDS
HP declaration
Resources

Datasheets and design resources

Datasheets, design guidance and supplier documentation for Polypropylene.

Download center

Access the most recent datasheet and supporting documentation maintained by our engineering team.

Polypropylene datasheet

Design guidelines

Explore printable geometry recommendations, wall thickness tips, and finishing playbooks for MJF.

View MJF design guide

Supplier compliance documents

Supplier declarations and test statements for this material.

MJF parts unpacked from the powder at a processing station
Advanced Manufacturing

Built with Precision MJF Technology

Polypropylene is manufactured using Multi Jet Fusion (MJF) technology, combining speed and consistency for production applications. Forge Labs' HP Jet Fusion 5200 systems run continuous build, cool and unpack cycles, so production lots run back to back.

Tolerance
±1.75% (min ±0.7 mm)
Production capacity
Multiple parts and assemblies nested in each build
Quality control
In-process monitoring and batch traceability for consistent part quality and material properties
Colours & finishes
Anthracite grey; bead blasted
Learn more about MJF technology
Frequently Asked Questions

Frequently asked questions about Polypropylene

Can't find the answer you're looking for? Reach out to our customer support team.

HP 3D High Reusability PP is genuine polypropylene with a tensile strength of 29 MPa and a tensile modulus of 1,600 MPa in both XY and Z, and a part density of 0.87 g/cm³, lighter than water. HP rates its chemical resistance excellent overall after immersion testing in acids, bases, organic solvents and aqueous solutions, gives it the top rating in its range for low moisture absorption, and it welds to injection-moulded polypropylene.
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STEP, STL, OBJ, 3MF and IGES supported

Manufacturing technologies
6
Engineering materials
50+
Part quantities
1-500+