Our PolyJet design guidelines help engineers design parts with exceptional surface finish, fine feature resolution, and multi-material capability. This guide covers critical considerations including minimum wall thickness, feature size, support removal, and part orientation so parts print accurately and are optimized for high-detail prototypes, visual models, and complex multi-material assemblies.
Build Volume
380 × 284 × 380 mm
General Tolerance
±0.2% (min ±0.2 mm)
Min. Wall ThicknessMinimum Wall Thickness
0.6 mm
Min. Hole DiameterMinimum Hole Diameter
See holes section
PolyJet is a precision 3D printing technology that uses inkjet heads to deposit liquid photopolymer resins in ultra-thin layers. The ability to combine up to 3 different materials in a single build makes it ideal for multi-material prototypes, overmolds, and complex assemblies.
These PolyJet design guidelines outline critical considerations for multi-material design, support removal, tolerances, and surface quality. Following these practices ensures optimal results for both functional prototypes and presentation models.
380 × 284 × 380 mm (15 × 11.2 × 15 in)
Our Stratasys J750 DAP and Connex3 printers offer a maximum build volume of 380 × 284 × 380 mm (15 × 11.2 × 15 in), accommodating both small detailed components and larger assemblies. The system operates with a precise 28-micron layer height for exceptional detail resolution.
NoteMulti-material builds require multi-body STEP files with separate bodies for each material assignment.
±0.2% (min ±0.2 mm)
PolyJet achieves dimensional accuracy with tolerances of ±0.2% (min ±0.2 mm). Parts with large flat surfaces may experience slight warping, so avoid these geometries when tight tolerances are critical.
TipInclude engineering drawings for parts requiring specific tolerances.
28 Microns
The ultra-fine 28-micron layer height provides exceptional detail resolution and smooth surface finish. This precision enables fine features, sharp edges, and intricate geometries that would be difficult to achieve with other 3D printing technologies.
NoteThe fine layer height minimizes stepping artifacts on curved surfaces and angled features.
Smooth, Ra 1-3 μm
PolyJet parts emerge with smooth, injection-molded quality surface finish straight from the printer. The combination of fine layer height and precise material deposition results in minimal post-processing requirements for most applications.
TipGel-like support material removes cleanly without leaving marks on supported surfaces.
Wall thickness requirements vary based on material type and support conditions. Multi-material designs require careful consideration of material transitions and interface bonding.
0.6 mm (0.8 mm recommended)
Rigid materials like RGD450 require a minimum wall thickness of 0.6 mm, though 0.8 mm is recommended for optimal strength and durability. Thinner walls may be fragile and prone to cracking during support removal.
Recommendations
1.0 mm minimum
Flexible materials like Agilus30 require thicker walls (minimum 1.0 mm) to maintain structural integrity. These materials are designed for gaskets, overmolds, and soft-touch applications.
Recommendations
Design Considerations
Multi-material interfaces require careful design to ensure proper bonding between materials. The chemical bonding between materials during printing creates strong interfaces when properly designed.
Recommendations
PolyJet excels at fine detail reproduction due to its 28-micron layer height and precise material deposition. Features can be much smaller than other 3D printing technologies.
Minimum Width and Depth: 0.2 mm
Engraved features can be as small as 0.2 mm in width and depth due to the precision of the inkjet heads. The smooth surface finish preserves fine details without layer line interference.
Recommendations
Minimum Width and Height: 0.2 mm
Raised features benefit from the smooth surface finish and can be reproduced with exceptional clarity. The gel-like support material supports overhanging details without surface marks.
Recommendations
Minimum: 8pt (embossed), 10pt (engraved)
Text can be much smaller than other 3D printing technologies due to the precision of PolyJet. Sans-serif fonts work best for small text applications.
Recommendations
Clearances for moving parts and assemblies can be tighter than other 3D printing technologies due to the precision and smooth surface finish of PolyJet.
0.2 mm
The smooth surface finish and precision of PolyJet allows for tighter clearances than other 3D printing technologies. A minimum of 0.2 mm clearance is recommended for moving parts.
Recommendations
0.3-0.5 mm thickness
PolyJet excels at printing living hinges using flexible materials. Design hinges 0.3-0.5 mm thick for optimal flexibility and durability.
Recommendations
Design for material properties
Multi-material capabilities enable snap-fits with rigid tabs and flexible clips in single builds. Design based on material properties and intended use.
Recommendations
PolyJet uses gel-like water-soluble support material that enables complex geometries and removes cleanly without surface marks.
Water-soluble gel support
The gel-like support material dissolves in water and can be removed through water jetting and manual cleaning. This enables complex internal geometries and overhangs.
Recommendations
2-3 mm diameter minimum
Hollow parts filled with support material require drain holes for complete removal. Design multiple holes for complex internal geometries.
Recommendations
All angles supported
Unlike other 3D printing technologies, PolyJet can print any overhang angle due to its comprehensive support system. This enables maximum design freedom.
NoteDesign freedom allows for complex geometries impossible with other technologies.
PolyJet's unique multi-material capability enables complex assemblies with integrated soft and hard components in single builds.
Multi-body STEP files required
Multi-material parts require multi-body STEP files where each component is modeled as a separate body. Our team assigns materials based on design intent and requirements.
Recommendations
Shore A30-A95 range
By blending rigid and flexible materials, PolyJet can create custom shore hardness values from A30 to A95 in precise ratios for specific applications.
Recommendations
Integrated multi-material design
Create overmolds with rigid substrates and flexible covers in single builds. This eliminates assembly requirements and ensures perfect fit.
Recommendations
