MJF 3D Printing: The Ultimate Guide [+ Free Cost Calculator]
Explore Multi Jet Fusion — the fastest & most functional polymer 3D printing technology — with Unionfab’s ultimate guide.
Introduction
Need rapid production of durable, high-precision plastic parts? Multi Jet Fusion (MJF) is one of the most advanced 3D printing technologies available today—up to 10× faster than SLS, with excellent strength, fine detail, and smooth finishes straight off the printer.
In this guide, we'll first dive into the essentials of MJF, covering how it works, its benefits, applications, and the materials and post-processing techniques it involves.
Next, we’ll compare MJF with other leading 3D printing technologies to help you determine the best fit for your project.
Finally, we'll share design tips, cost insights, and guidance on selecting the ideal MJF service provider in 2025—ensuring the best outcome for your needs.
What is MJF 3D Printing?
Developed by HP, Multi Jet Fusion (MJF) is a powder bed fusion 3D printing process designed to produce functional, end-use plastic parts with industrial-grade performance. It primarily uses nylon-based materials like PA12 and PA11.
How Does Multi Jet Fusion Work?
Instead of using lasers like SLS, MJF jets a fusing agent and detailing agent onto a powder bed, then fuses the material using infrared light. This speeds up the process and ensures consistent quality across builds.
Now let’s explore how this technology works under the hood:
Source: MIT Fab Lab
Multi Jet Fusion builds parts layer by layer using a precise combination of fusing agents, detailing agents, and infrared energy.
Unlike SLS, which sinters powder point-by-point using a laser, MJF fuses entire cross-sections of a layer in a single pass, significantly boosting efficiency.
At the heart of this speed is HP’s dual-carriage system:
One carriage selectively jets fusing and detailing agents onto the powder bed.
The second carriage immediately follows with infrared energy, fusing the powdered areas marked by the agents.
This unique system enables simultaneous recoating and fusing, eliminating downtime between layers and making MJF up to 10x faster than selective laser sintering (SLS).
The result? High-quality, functional parts with excellent mechanical properties, minimal visible layer lines, and smoother surfaces—perfect for industries like automotive, medical, and aerospace.
Key Advantages of MJF
Multi Jet Fusion (MJF) offers a variety of benefits that make it an ideal choice for high-quality, rapid production. Below are the key advantages of MJF that set it apart from other 3D printing technologies:
● Ultra-fast Production
Up to 10× faster than SLS—ideal for rapid prototyping and small production runs.
● Functional Strength
Comparable to injection molding—great for parts that need to withstand stress and wear.
● High Precision
Supports complex geometries and fine details, making it suitable for intricate designs.
● Smooth Surface Finish
Parts come out with a uniform texture, ready for coloring and post-processing.
● Reduced Post-Processing
MJF produces fully functional parts that often require little to no post-production, reducing time and effort for finishing processes.
● Shorter Lead Times
MJF’s advanced automation allows for faster production cycles with minimal human intervention, ensuring quick turnaround times while maintaining high-quality results.
Common Applications of MJF
Multi Jet Fusion (MJF) is widely recognized for its versatility, making it a perfect fit for various industries and applications. With its speed, strength, and precision, MJF is used to produce everything from functional prototypes to end-use parts.
Below are some common applications where MJF technology shines:
Industry | Applications | Parts Made by Unionfab | Key Benefits |
|---|---|---|---|
Automotive | Functional parts, in-car brackets | 
| Heat-resistant, lightweight |
Medical | Prosthetics, orthopedic braces, medical instruments | 
| Custom-fit, biocompatible materials |
Consumer Electronics | Complex components, impact-resistant parts | 
| High detail, durable |
Industrial Manufacturing | Jigs, custom tools, device casings | 
| Strong, precise, customizable |
Material Options for MJF 3D Printing
In this section, we'll walk you through the most popular materials for MJF 3D printing. First, we’ll give you a quick overview of the materials commonly used in MJF. Then, we’ll dive into a more detailed comparison of their key properties, so you can see how each one stacks up and choose the best fit for your project.
Overview of MJF Materials
Multi Jet Fusion (MJF) offers a wide range of materials that enable high-quality, rapid production of functional parts. The most commonly used materials in MJF are polyamide-based powders, each with unique properties suited for specific applications.
Below is an overview of the materials available, ranked by their frequency of use in MJF 3D printing.
Material Name | Material Description | Key Properties | Notable Features | Best For |
|---|---|---|---|---|
a polyamide powder synthesized from petroleum-based materials | ✔ High strength & stiffness ✔ Excellent chemical resistance ✔ Great dimensional stability | ✅ Strong & durable ✅ Sharp details ✅ Cost-effective | ● Functional prototypes ● End-use parts ● Industrial & automotive components | |
a 40% glass bead-filled Nylon PA12 | ✔ High stiffness ✔ Heat resistant ✔ Rigid & dimensionally stable | ✅ 40% glass bead filling ✅ Less warping ✅ Ideal for mechanical strength | ● Jigs & fixtures ● Load-bearing parts ● Structural components | |
a bio-based polyamide powder material derived from renewable resources such as plants or castor oil | ✔ More flexible than PA12 ✔ High impact resistance ✔ Bio-based & eco-friendly | ✅ Greater ductility ✅ High fatigue resistance ♻ Sustainable material | ● Medical devices ● Wearables ● Hinges, snap-fits & impact parts | |
Polypropylene (PP) | a thermoplastic material | ✔ Lightweight & flexible ✔ Excellent chemical resistance ✔ Good fatigue resistance | ✅ Watertight capabilities ✅ Low density ✅ Cost-saving for high-volume | ● Automotive reservoirs ● Medical housings ● Fluid systems |
Thermoplastic Polyurethane | ✔ Rubber-like flexibility ✔ High wear & abrasion resistance ✔ Multiple Shore options | ✅ Impact absorbing ✅ Highly elastic ✅ Great for soft-touch surfaces | ● Footwear ● Seals & gaskets ● Ergonomic components |
In-Depth Comparison of MJF Material Properties
Building on the previous section, we now dive deeper into the specific properties of each MJF material. In this comparison, we evaluate key performance metrics such as tensile strength, stiffness, impact strength, flexibility, durability, and more.
The following bar chart offers a visual representation of how each material measures up across these properties, helping you make informed decisions based on your project requirements.
Below is a table that provides a more detailed breakdown of the properties covered in the bar chart above.
Property | Nylon PA12 | Nylon PA12 GB | Nylon PA11 | Polypropylene (PP) | TPU |
|---|---|---|---|---|---|
Tensile strength | ⭐️⭐️⭐️⭐ ️~45-48 MPa | ⭐️⭐️⭐ ️~30 MPa | ⭐️⭐️⭐️⭐️⭐️ ~48 MPa | ⭐️⭐️⭐ ~️30 MPa | ⭐️⭐ ~️10 MPa |
Stiffness | ⭐️⭐️⭐️⭐ ️Good stiffness for structural stability. | ⭐️⭐️⭐️⭐️⭐️ Excellent stiffness, ideal for rigid parts. | ⭐️⭐️⭐️⭐ ️Balanced stiffness and flexibility. | ⭐️⭐️⭐ ️Moderate stiffness for general use. | ⭐️⭐ ️Low stiffness, highly elastic. |
Impact strength | ⭐️⭐️⭐️⭐ ️Good impact resistance for daily applications. | ⭐️⭐ ️Low impact resistance due to glass bead filling. | ⭐️⭐️⭐️⭐️⭐ ️Superior impact resistance, tough and durable. | ⭐️⭐️⭐️⭐ ️High impact resistance, resistant to shocks. | ⭐️⭐️⭐ ️Moderate impact resistance, absorbs collisions well. |
Flexibility | ⭐️⭐️⭐ ️Moderate flexibility, balanced for various applications. | ⭐️⭐ ️Low flexibility, more rigid material. | ⭐️⭐️⭐️⭐ ️High flexibility, ideal for parts requiring bending or flexibility. | ⭐️⭐️⭐️⭐️ Very flexible, great for soft, bendable parts. | ⭐️⭐️⭐️⭐️⭐ ️Extremely flexible, highly elastic, ideal for wearables. |
Durability | ⭐️⭐️⭐️⭐ ️Durable, resistant to wear and tear under normal conditions. | ⭐️⭐️⭐️⭐️⭐ ️Excellent durability, performs well under extreme conditions. | ⭐️⭐️⭐️⭐️⭐ ️Very durable, performs excellently in tough environments. | ⭐️⭐️⭐️⭐ ️Good durability, suitable for long-lasting parts in regular conditions. | ⭐️⭐️⭐️⭐ ️High durability, suitable for wear-resistant applications. |
Heat Resistance | ⭐️⭐️⭐️⭐ ~120–150°C, slightly higher than Nylon 11 | ⭐️⭐️⭐️⭐️⭐ ~150–200°C | ⭐️⭐️⭐ ️~130°C | ⭐️⭐️⭐️⭐ ️Good heat resistance (100–120°C). | ⭐️⭐️⭐ ️High heat resistance (150°C), ideal for high-temperature environments. |
Thermal conductivity | ⭐️⭐ ️Low thermal conductivity, not ideal for heat dissipation. | ⭐️⭐️⭐️⭐️⭐ ️High thermal conductivity, great for heat dissipation. | ⭐️⭐ ️Low thermal conductivity, similar to PA12. | ⭐️⭐️⭐ ️Moderate thermal conductivity, dissipates heat reasonably well. | ⭐️⭐ ️Low thermal conductivity, not ideal for heat management. |
Ease of post-processing | ⭐️⭐️⭐️⭐ ️Easy to process with standard post-processing techniques. | ⭐️⭐️⭐️⭐ ️Easy to process, similar to PA12. | ⭐️⭐️⭐️⭐ ️Easy to work with, minimal post-processing required. | ⭐️⭐️⭐ ️Moderate post-processing required. | ⭐️⭐️⭐ ️Moderate difficulty, may require more work than PA12. |
Biocompatibility | ⭐️⭐️⭐ ️Good biocompatibility, suitable for some medical uses. | ⭐️⭐️⭐ ️Moderate biocompatibility, suitable for certain medical parts. | ⭐️⭐️⭐️⭐️⭐ ️Very high biocompatibility, ideal for medical and body-contact parts. | ⭐️⭐️⭐ ️Moderate biocompatibility, can be used in medical applications. | ⭐️⭐️⭐️⭐ ️High biocompatibility, used in medical and wearable devices. |
Cost-effectiveness | ⭐️⭐️⭐️⭐ ️Most affordable among nylons, mature production & sufficient supply. | ⭐️⭐️⭐ ️More expensive than PA12, due to glass bead filling and modified processing. | ⭐️⭐ ️Most expensive (bio-based raw material, complex production process). | ⭐️⭐️⭐️⭐️⭐ ️Most cost-effective overall, low raw material and production costs. | ⭐️⭐️⭐ ️Moderately priced, higher than PA12 but lower than PA11. |
Key Takeaways
● Nylon PA12: Strong, durable, and cost-effective, ideal for functional prototypes and end-use parts.
● Nylon PA12 GB: Reinforced with glass beads for higher stiffness and durability, perfect for structural and load-bearing parts.
● Nylon PA11: Bio-based, flexible, and impact-resistant, great for medical devices and wearables.
● Polypropylene (PP): Lightweight, cost-effective, and chemical-resistant, suitable for automotive and medical applications.
● TPU: Highly flexible and wear-resistant, best for impact-absorbing parts like footwear and seals.
If you want to learn more about nylon 3D printing or TPU 3D printing, be sure to check out our dedicated guides.
Post-Processing Techniques for MJF 3D Printing
Post-processing is essential to improve aesthetics, surface quality, and environmental performance—especially for end-use or customer-facing products.
Cleaning & Surface Smoothing: Bead blasting or media tumbling removes residual powder and provides a uniform matte finish.
Dyeing: Since MJF parts are naturally gray, dyeing is used to achieve deep black or custom colors (e.g., red, blue) for branding or cosmetic appeal.
Polishing: Mechanical polishing or chemical smoothing enhances surface smoothness for a semi-gloss, consumer-ready finish.
Coating & Sealing: Various coatings improve wear resistance, waterproofing, or chemical durability, making MJF parts suitable for demanding environments.
MJF vs. SLS vs. SLA vs. FDM: Which 3D Printing Technology Is Right for You?
Different 3D printing technologies bring unique advantages depending on your project goals. The radar chart below offers a quick visual comparison of Multi Jet Fusion (MJF) against other major 3D printing processes before we dive into a more detailed breakdown.
The radar chart above gives a quick visual overview of how MJF, SLS, SLA, and FDM stack up in terms of key performance metrics. To dive deeper into the specifics of each technology, we've provided a detailed breakdown in the table below, highlighting their unique features and strengths.
Feature | ||||
|---|---|---|---|---|
Technology | Inkjet + infrared fusion of powder | Laser sintering of powder | UV curing of liquid resin | Extrusion of melted filament |
Speed | Fastest (10× faster than SLS) | Slower due to laser scanning | Moderate (depends on resin curing) | Slow, layer-by-layer extrusion |
Material | Nylon (PA 12, PA 11), TPU | Nylon, TPU, composites | Photopolymer resin | PLA, ABS, PETG |
Part Strength | High (close to injection molding) | Strong and durable | Brittle, best for aesthetics | Moderate strength |
Surface Finish | Smooth, uniform, suitable for dyeing | Slightly rough, requires post-processing | Best detail & smoothest finish | Layer lines visible |
Best For | Functional prototypes, low-volume production | Industrial parts, functional prototypes | High-detail prototypes, casting patterns | Hobby projects, low-cost prototyping |
Cost | $$ Efficient powder reuse reduces cost | $$ – $$$ Diverse material options with a wide price range | $ -$$$ Diverse resin options with a wide price range | $ Most affordable |
Key Takeaways:
● MJF offers the best balance of speed, performance, and scalability, making it ideal for industrial-grade polymer parts. It delivers high strength, fine detail, and consistent quality, all while remaining cost-effective.
● SLS is perfect for industrial applications where strength and durability are paramount, but it’s slower than MJF.
● SLA excels in creating high-detail prototypes with smooth finishes, but it's best for aesthetic applications, as its parts tend to be more brittle.
● FDM is the most affordable technology, making it a great choice for hobbyists or low-cost prototyping, though it may not offer the same level of precision or strength as the other methods.
Still unsure which 3D printing technology fits your project best? Our experts at Unionfab are here to help you navigate the options and choose the solution that works for you.
Key Design Tips for MJF 3D Printing
Designing for Multi Jet Fusion (MJF) requires attention to detail and an understanding of the unique characteristics of the technology. While MJF offers excellent detail and high strength, poor design choices can lead to issues like warping, powder entrapment, or a lack of dimensional accuracy.
To help you design more reliable and functional parts, here are some key tips to keep in mind:
● Maintain Proper Wall Thickness: Walls should be between 0.7mm and 2.0mm thick. Avoid extreme thickness variations to prevent warping and internal stress.
● Reinforce Thin Features: Thin or long features, like hooks, can warp or snap. Use fillets or ribs to reinforce these areas and avoid sharp transitions.
● Optimize Internal Structures: For hollow parts, add drain holes (5mm or larger) to allow for proper powder evacuation and prevent poor post-processing.
● Allow for Proper Part Clearance: Ensure there’s a clearance of at least 0.7mm between moving parts to prevent fusion or misalignment.
● Avoid Large Flat Surfaces: Large flat areas are prone to warping. Use lattices, ribs, or cutouts to reduce thermal stress.
● Minimize Warping in Long Parts: Avoid aspect ratios greater than 10:1, and use smooth transitions to balance cooling and reduce distortion.
● Design for Snap-Fits: Ensure snap-fits are flexible enough for repeated stress. Use smooth transitions for better performance.
● Ensure Proper Powder Drainage: Add escape channels or exit holes in deep cavities to avoid powder entrapment, especially for threaded parts.
By applying these design best practices, you can significantly improve the manufacturability and performance of your MJF parts, ensuring that they are functional, durable, and easy to post-process.
MJF 3D Printing Cost Breakdown
Wondering how much MJF really costs? Here's a full look at the key cost drivers—whether you're producing in-house or outsourcing to a service provider.
In-House Production Cost
Key cost factors in MJF printing include:
Machine Cost
Drawback: Industrial MJF systems like the HP Jet Fusion 5200 range from $200,000 to $400,000, depending on build size and automation features.
Advantage: Despite the high upfront investment, high throughput and material reuse help significantly reduce the long-term cost per part—especially at scale.
Material Cost
Drawback: MJF uses nylon-based powders like PA12, typically priced at $50–$80 per kilogram, which can add up quickly.
Advantage: However, the ability to reuse 70–80% of unused powder keeps material waste and ongoing costs low, particularly in batch production environments.
Post-Processing Cost
Drawback: While some cleanup is still needed, basic post-processing like bead blasting can cost $3–$10 per part, depending on geometry and surface requirements.
Advantage: MJF parts don’t require support structures, resulting in less manual labor, shorter lead times, and smoother workflows.
ROI Analysis: Is MJF Worth the Investment?
While MJF machines come with a high upfront cost, their superior production speed, minimal post-processing, and efficient powder reuse can deliver a strong return on investment (ROI), depending on production volume.
You’ll benefit most if:
You're producing 10,000+ parts per year
You need rapid iteration without supplier delays
You want tight control over design and production workflows
When to Use a 3D Printing Service Instead?
Outsourcing to a service provider like Unionfab can be smarter in many scenarios:
In-House (DIY) | Outsourcing (Via Service Provider) |
|---|---|
✔ High print volume (>10,000 parts/year) | ✔ Low to mid volume (<5,000 parts/year) |
✔ Need for fast internal turnaround | ✔ Occasional or on-demand printing |
✔ Full control over design iterations | ✔ Access to wide material/finish options |
❌ High initial capex & maintenance | ✔ Zero upfront investment |
❌ Limited material inventory | ✔ One-stop access to latest technologies |
Get real-time pricing for your MJF parts—use our Cost Calculator to see your estimated cost instantly.
How to Choose the Right MJF 3D Printing Service in 2025?
With so many MJF 3D printing providers on the market, it’s easy to feel overwhelmed. Pricing, lead times, materials, and reliability all vary widely.
To help you choose wisely, we’ve created a detailed side-by-side comparison of the top MJF 3D printing services in 2025.
Compare Top MJF 3D Printing Service Providers in 2025
We evaluated the top service providers based on materials offered, build capacity, lead times, sample costs, and Trustpilot reviews.
Service Provider | Profile | Material | Lead Time | *Sample Cost | Trustpilot |
|---|---|---|---|---|---|
PCBWay | Leading PCB Manufacturer and Prototyping Services | PA 12 | 3-4 Days | $61.84 | |
Unionfab | China-based Global 3D Printing Service Provider; Six In-house Factories | •Nylon 12 (PA 12) | 3 Days | PA 12: $51.9 | |
Xometry | Global Factory-less 3D Printing Supply Chain Platform | •Nylon 11 | •Expedite: 1- 4 Days | Nylon | |
Protolabs Network | A US-based Global 3D Printing Service Provider | •PA 12 | 3-5 Days | PA 12: $84.28 | |
Stratasys | A US-based Global 3D Printing Service Provider | Nylon 12 | 3 | $75.91 | Not listed |
RapidDirect | China-Based Manufacturing services | Nylon 12 | 5 | $78.35 |
Key Takeaways: Who Comes Out on Top?
Best Value: Unionfab – starting from $51.90; reliable in-house production.
Fastest Turnaround: Unionfab and Stratasys offer 3-day lead times. Xometry provides 1–4 days with expedited service.
Flexible Options: Xometry – Offer TPU and PP, Flexible Delivery Speeds.
Highest Trustpilot Rating: Tie between Xometry and RapidDirect (4.7), Unionfab follows closely at 4.6.
What to Look for in an MJF Printing Service
Beyond cost and speed, consider these key criteria:
Industrial-Grade EquipmentEnsure the provider uses professional HP MJF 4200 or 5200 printers for consistent quality.
Finishing CapabilitiesLook for post-processing options like dyeing, polishing, sealing, or coating—essential for end-use parts.
Transparent PricingChoose services offering instant quotes, volume discounts, and no hidden fees.
Quality AssuranceNeed tight tolerances? Look for providers that offer CMM inspection or dimensional reports.
Logistics & SupportGlobal shipping, real-time support, and fast communication are vital for meeting deadlines and reducing risk.
Why Unionfab Is the Smart Choice for MJF Printing
With 20+ years of manufacturing experience, Unionfab is one of the few providers offering full-spectrum industrial MJF 3D printing with unmatched value, speed, and service:
In-House Production Scale
10× HP MJF 4200 printers
8× HP MJF 5200 printers
6 dedicated production facilities across China
⠀Fast, Accurate, and Reliable
3-Day standard lead time
CMM inspection for critical tolerances
Full batch traceability and documentation
⠀Hassle-Free Ordering, Support & After-Sales
Real-time quoting & order tracking
24/7 online support, global shipping & after-sales policy
Advanced Finishing Options at Unionfab
In addition to standard post-processing, Unionfab offers a wide variety of professional-grade plastic finishing techniques to meet specialized requirements:
Laser Engraving | Regular Spray Paint | Nickel Plating | Tin Plating | Zinc Plating |
|---|---|---|---|---|
Crackle Paint | Matte Finish | Glossy Finish | Sandblasting | Texture Etching |
Mold Etching | Electroplating | Electrolytic Plating | Vacuum Plating | Silk Screen Printing |
Pad Printing | Water Transfer Printing | Heat Transfer Printing | Hot Stamping | UV Printing |
Whether you want your part to look premium, resist harsh conditions, or meet specific regulatory standards, Unionfab’s finishing capabilities have you covered!
QA Report
In addition to delivering cost-effective prints, we also offer quality assurance services and can send the QA report with the shipment. Btw, if you haven’t used Unionfab’s 3d printing service yet, sign up now to get a 10% discount on your first order!
Customer Feedback
Here’s what customers are saying about Unionfab on Trustpilot:
Customer | Feedback |
|---|---|
Brem from US | ★★★★★ Surprised by the Low Price, but glad I took the risk. I was surprised and put off by the extremely low prices, and sometimes the offers of free parts, but I thought it was worth trying $20 at Unionfab, and I was not disappointed. I did their metal 3D printing service and I got my part super quick, I am looking to CNC some parts in the future and will use Unionfab for it most likely! Better customer service than most American companies, and cheaper too. |
Customer from JP | ★★★★★ This was my second time using it. As with the first time, I am very satisfied with the unit price and delivery date. Regarding the delivery date, it was very speedy and helpful. I would like to use it again in the future. |
Sean. S from US | ★★★★★ Trustworthy. The price of my 3D print was very competitive. Arrived about 10 days after submitting the 3D file (from China). The prints were high detail resin, and I'm very satisfied with the quality. Will definitely have them print more in the near future. Sent via UPS with tracking. |
Customer from JP | ★★★★ It was almost perfect. It was almost perfect and didn't have any issues on products. It was absolutely perfect if I can use OCS express to ship to Japan because their airfare cost is quite reasonable (cheap ship to Japan). |
Printed Online from FR | ★★★★★ Très professionnel Très professionnel, à l'écoute et réactif. Je recommande! |
UK_customer from GB | ★★★★★ Reliable. Multiple transactions - fast, reliable, great communication. |
FAQs About MJF 3D Printing
Can MJF parts be used outdoors?
Yes! PA12 parts offer solid moisture and abrasion resistance. For long-term outdoor use, adding UV-resistant coatings is recommended to prevent fading or brittleness.
What’s the minimum order volume for MJF parts?
At Unionfab, there is no MOQ. Whether you need one prototype or 10,000+ parts, we scale to your needs.
Is MJF waterproof?
Right out of the printer, MJF parts are not fully waterproof due to the porous nature of nylon powder. That said, with post-processing techniques like sealing, vapor smoothing, or coating, you can significantly improve water resistance.
So yes, waterproofing is possible—just not entirely "as-printed."
Does MJF printing need supports?
One of the major advantages of MJF is that it doesn’t require support structures. The surrounding powder provides all the support your part needs, which means more design freedom, less material waste, and faster turnaround times.
What are the advantages of MJF?
MJF is known for its:
High detail and dimensional accuracy
Smooth, consistent surface finish
Excellent mechanical strength (especially with PA12)
No support structures needed
Great for both prototyping and functional end-use parts
Cost-effective for low to mid-volume production
What are the disadvantages of MJF?
Like any process, MJF isn’t perfect for everything. Here’s where it has some limitations:
Limited material selection compared to other 3D printing methods
Surface finish is matte and slightly grainy without post-processing
Parts may require sealing for water- or air-tightness
Initial equipment cost (for in-house use) is relatively high
