SLA vs. PolyJet
Compare vat photopolymerization and material jetting by the named resin system, material map, support and cleaning route, appearance target and functional validation.
Choose the material architecture the prototype must demonstrate
SLA selectively cures resin in a vat and commonly follows printing with washing and a prescribed post-cure. PolyJet jets and UV-cures photopolymer droplets, enabling compatible systems to place multiple colors or material behaviors in one build.
SLA
A qualified single-resin route
Screen SLA for fine features, smooth surfaces and a named resin whose wash, cure and service behavior fit the test.
PolyJet
A mapped appearance or material system
Screen PolyJet when the prototype needs compatible rigid, flexible, transparent or color regions placed together and the supported surfaces can be cleaned.
Boundary
Photopolymer is not a property
Resin name, printer, print mode, cure or support-removal state, geometry and exposure define the evidence. Do not assign one product’s result to the process family.
One resin volume and a material map solve different prototype problems
The useful distinction is not “detail versus detail.” It is whether the part needs a qualified SLA formulation throughout or a PolyJet build that communicates color, texture, transparency or local compliance through compatible material regions.
| Intent | SLA route | PolyJet route |
|---|---|---|
| Single-material functional test | Select a named engineering resin and follow its prescribed wash and cure before testing. | Select one named model material and support system; confirm that its exposure and load scope fit the test. |
| Rigid body with soft grip or seal | Usually print or source separate qualified components and assemble them. | A compatible multi-material system can place rigid and flexible regions together; validate the interface and aging. |
| Color and texture review | Paint, coat or assemble samples when the chosen resin does not provide the target appearance. | Map colors, opacity and textures in the build data, then approve a physical sample under controlled lighting. |
| Clear viewing region | Choose a clear resin and design access for support removal, sanding and polishing if needed. | Choose a compatible transparent material and print mode; supported faces and material thickness still affect appearance. |
| Regulated use | Use the exact validated resin, printer and post-cure workflow for the stated contact/use category. | Use the exact model/support materials, printer, cleaning and documented contact/use scope. |
Keep manufacturer product names and conditions in the comparison
“ABS-like,” “rubber-like” and “clear” describe targets, not equivalence to molded stock. Product pages and data sheets provide useful screening evidence only for the documented workflow.
| Manufacturer product | Candidate use | Condition boundary |
|---|---|---|
| Formlabs Tough 2000 Resin V2 | SLA candidate for a sturdy functional prototype where its documented behavior matches the load. | Form 4-series compatibility, print settings, wash, post-cure, orientation, temperature and test method. |
| Formlabs Clear Resin V5 | SLA candidate for transparent geometry or fluid/optical development after suitable finishing. | Printed and cured condition, wall thickness, support location, polishing access and exposure medium. |
| Stratasys Vero family | Rigid PolyJet appearance and fit models, including compatible color and digital-material workflows. | Printer/material compatibility, print mode, support contact, color recipe, section thickness and lighting. |
| Stratasys Agilus30 family | Flexible PolyJet regions for tactile, grip, seal or overmold-like prototypes. | Printer and blend, local thickness, interface geometry, cleaning, aging and the required cycle/load test. |
The local material library provides family-level screening. Until a named resin product is cataloged there, use the linked manufacturer source rather than implying a FabDigit-stocked formulation.
Support contact controls appearance, access and acceptance
SLA parts need resin removal, drying and product-specific post-cure after support removal. PolyJet parts need removal of a compatible gel-like, breakaway or soluble support. Fragile details and enclosed regions can control both routes.
- Supply a visible-face map. Identify gloss, texture, color and transparency zones so orientation and support contact can be planned around the review surfaces.
- Open every cleaning path. Check trapped resin or wash fluid for SLA and trapped support or cleaning media for PolyJet. A drain opening alone does not prove a branched cavity is clean.
- Inspect the delivered state. Measure fits after SLA cure and after any PolyJet cleaning, polishing or coating. Judge color and transparency on a physical approval sample.
Continue with the SLA design guide, PolyJet design guide and 3D printing finishing guide.
Test the prototype behavior it was selected to represent
A comparison sample should isolate the decision: load and creep for a functional resin, color and gloss for an appearance model, or interface durability for a multi-material part. Do not combine every question into one subjective review.
| Decision | Representative sample | Acceptance evidence |
|---|---|---|
| Functional resin | Loaded feature with production wall, orientation, wash/cure and expected exposure | Dimensional result plus load, deflection, creep, impact or environmental test as applicable |
| Color/material map | Small assembly containing each rigid, flexible, transparent and color boundary | Approved physical sample under named lighting, handling and aging conditions |
| Supported surface | Critical face printed in the intended orientation and cleaned by the production route | Surface comparator or approved master plus post-clean dimensional inspection |
| Clear or fluid feature | Representative wall, channel and accessible finishing route | Optical or leak/flow test using the actual medium, pressure, duration and finish |
Frequently asked questions
Is PolyJet more accurate than SLA?
Neither process has one accuracy value. Compare the applicable printer/material specification, geometry, support condition and delivered finish, then define the dimensions and inspection method the part must meet.
Can SLA make a multi-material part like PolyJet?
Typical SLA production uses one resin in a build. Separate SLA parts can be assembled or overmolded, while compatible PolyJet systems can jet multiple model materials in one build. Validate every interface and material combination.
Do PolyJet parts need post-curing?
Stratasys describes model droplets as UV-cured during deposition, but the finished part still needs support removal and any specified cleaning or finishing. Follow the exact printer and material workflow.
Which process is better for a clear prototype?
The answer depends on viewing path, wall thickness, support contact, finishing access, optical acceptance and environmental exposure. Build a representative clear section and approve the delivered result.
Sources and further reading
- Formlabs — SLA wash and cure workflowManufacturer workflow showing that washing and product-specific post-cure complete the SLA route.
- Formlabs — Tough 2000 Resin V2Named SLA product with printer, print and post-cure conditions attached to published properties.
- Stratasys — PolyJet technologyJetting, UV cure, support removal and compatible multi-material capability.
- Stratasys — PolyJet materialsCurrent named product families and printer/material relationships.
- Stratasys — PolyJet support materialsSupport-removal methods and printer compatibility are support-product specific.
Specify the details that make the part work.
Upload your CAD and drawing with the material, quantity, finishing and critical dimensions. Confirm the manufacturing route before production.