Plan material boundaries, colour, surface finish and support removal for realistic prototypes. Select the resin and test conditions when function matters as much as appearance.
Material jetting can assign different model resins to regions within one cross-section. That makes colour and soft/rigid boundaries native build data, while a separate gel-like support material still has to be removed from overhangs and cavities.
Prepare
Build preparation resolves geometry, material assignments, textures and the glossy or matte strategy for supported surfaces.
Jet
Inkjet-style heads deposit tiny droplets of selected photopolymer and support material across the tray.
Cure
UV light cures the deposited droplets immediately. The platform indexes and the jet/cure sequence repeats.
Clean
Gel-like support is removed by the compatible manual or water-assisted route before cosmetic finishing and inspection.
The sequence follows Stratasys’ PolyJet technology and support documentation. Resin channels, digital-material recipes, support type and printer compatibility determine what can be combined.
PolyJet can place rigid and flexible photopolymers in one build on compatible systems. The file must communicate which region receives which material.
| Intent | Prepare | Check before approval |
|---|---|---|
| Rigid body with a soft grip | Distinct bodies sharing the intended interface | Remove ambiguous overlaps; they can produce incorrect material assignments. Do not add a universal 0.1 mm overlap. |
| Multiple colours | Body-to-colour mapping or a supported texture workflow | Confirm the receiving workflow and include all texture assets; a plain STL does not carry a texture map. |
| Softness | A named material blend and functional geometry | Shore hardness alone does not determine how a thin skin over a rigid core feels. |
| Clear window | Viewing region and accessible finish surfaces | Wall thickness, texture and processing affect clarity. Specify required optical performance separately. |
| Critical colour | A reference and an approved printed sample | Substrate, section thickness, finish and lighting affect colour; a screen preview is not an acceptance sample. |
Support strategy and resin choice affect fragile features. Specify the final function before using a manufacturer minimum.
| Feature | Manufacturer guidance | Design implication |
|---|---|---|
| Rigid wall | 0.6 mm general minimum example | The same guide recommends at least 1 mm for structural/load-bearing walls; the actual load still requires assessment. |
| Tall thin wall | Above 30 mm: review matte finish and support policy | A tall wall can need more support during printing and careful cleaning afterward. |
| Visible fine detail | 0.2 mm example | Visibility depends on material and colour; durable lettering may need larger features. |
| Colour appearance | Section thickness affects the result | The guide’s Pantone workflow uses at least 6 mm thickness. Use the applicable printer/material guidance and a sample. |
| Internal channels | Provide support-removal access | A printed opening does not prove support can be removed through a long, bent passage. |
| Moving assembly | Test the gap and cleaning route | A separate-fit part and a printed-in-place mechanism need different validation. |
These are examples from Stratasys design guidance, not a universal PolyJet tolerance or a promise for every resin, printer or application.
Choose a named resin and final processing state. Do not generalise the behaviour of an older rigid visual resin to every current PolyJet material.
Appearance
Select for geometry, colour and finish. Treat visual matching and optical quality as their own acceptance requirements.
Function
Digital ABS and newer ToughONE products support functional prototyping. Confirm material availability and use the exact cured-state data for your load case.
Compliance
A biocompatible resin does not certify any printed part. Required contact type, duration, printer, cleaning and sterilisation conditions must match the validated workflow.
For example, Stratasys publishes MED610 contact indications and processing conditions. Those should not be condensed into an unrestricted “medical-safe” label.
PolyJet product families cover rigid colour, transparent, rubber-like, tougher and workflow-specific materials. A digital blend can simulate a target feel without becoming the thermoplastic it resembles.
| Material family | Product examples | Selection direction | Performance evidence to compare |
|---|---|---|---|
| Rigid colour / opaque | Vero family VeroVivid | CMF reviews, display models and detailed rigid prototypes. | Specify printer, base/core colour, section thickness, print mode, viewing light and a physical colour/texture sample. |
| Transparent | VeroUltra Clear | Clear housings, lenses-as-form studies and fluid-visualization prototypes. | Separate light transmission or haze needs from resin identity; geometry, support contact and polishing access govern the final window. |
| Rubber-like | Agilus30 | Soft grips, overmold simulations, seals and flexible details. | Keep Shore hardness with tensile/tear test method and colour. Validate thin skins, repeated flexing and compression on the real geometry. |
| Functional rigid | Digital ABS Plus ToughONE | Snap, impact and handled functional prototype candidates. | Use the exact recipe/product and prescribed post-process; “ABS simulation” does not transfer production ABS creep, chemical or service-life data. |
| Biocompatible workflow | Biocompatible Clear MED610 | Specific contact applications under the documented workflow. | Match contact type/duration, printer, support removal, cleaning, sterilization and traceability. The label does not certify every finished device. |
These are official manufacturer examples, not a FabDigit stock list. Confirm printer/material compatibility, digital blend, colour, finish and any regulated workflow on the quote.
Use the live library to move from photopolymer families to grade pages and manufacturer products. Multi-material assignments and current machine/material availability remain order-specific and are confirmed with the quote.
3 material grades 0 manufacturer products
Explore the indexed grade and product pages here. A quote confirms the material, machine, finish and sourcing available for a specific order.
Support contact and print mode affect gloss. Finishing should be chosen with the material boundaries and fragile features in mind.
Required
Compatible supports are removed manually, with water pressure, brushing or the documented cleaning route. Cavities and soft/rigid edges need access.
Confirm: support type, water pressure, fragile details, internal cleanliness and allowed witness areas.
Native appearance
Exposed and supported regions can show different gloss. PolyJet colour is normally assigned during printing rather than added by nylon-style dyeing.
Confirm: visible-face map, print mode, core/section colour, lighting and an approved physical sample.
Secondary
Local finishing can blend witness marks or improve a clear window, but it may soften texture and material transitions.
Confirm: surface access, masking of flexible regions, edge definition and final optical or dimensional inspection.
Coating
A coating adds build and changes gloss; adhesion and solvent response depend on the exact photopolymer.
Confirm: primer/coating system, masking, colour reference, aging environment and assembled clearance.
A manufacturer accuracy specification describes a particular system and material condition. It is useful evidence, but not a tolerance for every PolyJet part.
Clearance is the hole diameter minus the shaft diameter. Both parts contribute to the final fit.
Minimum clearance = smallest hole − largest shaft. A nominal gap alone does not guarantee free movement.
Schematic illustrations; not to scale. Confirm the design for the chosen material, process and final use.
| Published specification | Value | Scope |
|---|---|---|
| Typical deviation below 100 mm | ±0.10 mm | Manufacturer specification for rigid models; confirm applicability to your geometry and finishing. |
| Typical deviation above 100 mm | ±0.20 mm or ±0.06% of lengthwhichever is greater | Do not extrapolate this to flexible resins or unrelated printer models. |
| High-quality layer example | 14 µm | Layer thickness is not the same quantity as dimensional accuracy. |
These values illustrate why printer and material must be named. FabDigit delivery, dimensional acceptance and available equipment are confirmed on the quote.
Use distinct material regions with unambiguous shared interfaces and identify the material for each body. Remove unintended overlaps; Stratasys warns they can cause incorrect material or colour assignment.
Stratasys design guidance gives 0.6 mm as a general rigid-wall example and at least 1 mm for structural walls. Material, height, load and cleaning can require more thickness.
No. Some resins prioritise visual realism while products such as ToughONE support functional prototypes. Select a named material and processing state, and validate the intended load, cycles and environment.
Not necessarily. Material, core colour, wall thickness, finish and viewing conditions affect appearance. Approve a physical sample for critical colours.
Support contact and the selected print mode affect surface texture and gloss. Identify the visible faces and agree a finish strategy or secondary finishing sample.
No. Layer thickness is a build increment. Use the specific printer/material accuracy information, then confirm the final dimensional limits and finishing state for the actual part.
Send the assembly with a material map, appearance reference, critical fits and intended use. Confirm the suitable material and finish on the quote.
