Introduction
When it comes to HP Jet Fusion 3D printing, the difference between a successful, high-performance part and one that falls short lies in design optimization and process knowledge. Few understand this better than Micah Chaban, Founder and VP of Sales at RapidMade, a company specializing in industrial 3D printing, engineering services, and production manufacturing. With years of experience guiding businesses through advanced additive manufacturing, Micah has helped industries—from aerospace to healthcare—leverage MJF technology for precision-engineered solutions.
In this in-depth conversation, Micah shares his expertise on best practices for HP Jet Fusion 3D printing, covering design strategies, common pitfalls, post-processing techniques, and how companies can benefit from working with RapidMade.
What makes HP Jet Fusion different from other 3D printing technologies?
“HP Jet Fusion is a game-changer in 3D printing. Unlike traditional methods like FDM, which extrudes plastic layer by layer, or SLA, which uses UV light to cure liquid resin, MJF is a powder-based process that fuses material with infrared heat. This means you get parts that are stronger, more precise, and produced much faster than SLS or other powder-bed technologies.
One of the biggest advantages is isotropic strength—the parts have nearly identical mechanical properties in all directions. That’s a huge deal for industries that need durable, functional parts, like aerospace, automotive, and medical manufacturing. MJF is also incredibly efficient because the powder that isn’t fused can be recycled and reused, reducing material waste and costs.”
What are the most important design considerations for MJF printing?
“Designing for MJF isn’t the same as designing for machining or even other 3D printing technologies. One of the most important factors is wall thickness. If your walls are too thin—say, under 0.3 mm in the XY plane or 0.5 mm in the Z direction—your parts may not fuse properly or could be too fragile. On the flip side, if walls are too thick, they can retain too much heat and warp.
Another critical aspect is print orientation. The way a part is positioned in the print bed affects accuracy, strength, and surface finish. By optimizing orientation, we can reduce warping, improve strength in load-bearing directions, and minimize visible layer lines.
And for interlocking parts or assemblies, you need to allow enough clearance. If there’s not enough space between moving parts—typically at least 0.7 mm—they can fuse together during printing.”
What’s the best way to reduce weight without sacrificing strength?
“There are three key approaches: hollowing, lattice structures, and topology optimization.
Hollowing is the simplest. Instead of printing a solid block, we remove unnecessary internal material while keeping structural integrity. The key here is ensuring a minimum wall thickness of 2 mm and adding drain holes (at least 5 mm in diameter) to remove unfused powder inside.
Lattice structures take it a step further. Rather than just hollowing, we replace the solid interior with a network of interconnected beams. These can be designed for maximum strength-to-weight efficiency, which is why they’re so common in aerospace and medical applications.
And then there’s topology optimization. This is where we use software like nTopology or Materialise Magics to analyze where the stress is actually distributed in a part. The algorithm removes material in areas that aren’t critical for strength, resulting in a lighter, stronger, and more efficient design.”
How accurate is MJF compared to traditional manufacturing?
“MJF is one of the most precise 3D printing technologies available today. We routinely achieve IT Grade 13 accuracy, which means most parts are within ±0.2 mm per 100 mm. That’s close to what you get with injection molding, and in some cases, it can even be better.
That said, accuracy depends on design complexity, part orientation, and material selection. Fine details—like embossed logos or small engraved text—should be at least 1 mm deep or tall to ensure readability. If you’re working on mission-critical dimensions, we always recommend iterating with test prints to refine tolerances before moving into production.”
What post-processing techniques improve MJF parts?
“The great thing about MJF is that it already has a better surface finish than SLS, but there are still ways to improve it.
We use bead blasting to remove excess powder and smooth the surface slightly. Dyeing is another common option—it allows us to give parts a uniform black color without affecting strength. If a customer needs a smoother, sealed surface, we offer vapor smoothing, which chemically alters the outer layer to reduce roughness and make the part more water-resistant.
For watertight applications, we sometimes apply sealants or coatings in post-processing, but even without them, MJF parts can be designed to hold liquids if the geometry is right.”
What industries benefit the most from MJF?
“Honestly, it’s hard to think of an industry that wouldn’t benefit!
Aerospace and automotive manufacturers use MJF for lightweight brackets and aerodynamic components. Medical device companies rely on it for custom prosthetics and surgical tools. And in consumer goods, we’re seeing more companies use it for wearables, high-detail enclosures, and sports equipment.
MJF is especially useful for companies that need low-to-mid-volume production, where injection molding is too expensive, but FDM or SLA don’t offer the required durability.”
What are some common mistakes designers make when working with MJF?
“The biggest mistake is not designing specifically for additive manufacturing. People often create parts as if they were machining or injection molding them, which leads to features that don’t print well or inefficient use of material.
Another common issue is ignoring thermal stress and warping risks. Long, thin parts tend to warp if they aren’t reinforced properly. Also, designers sometimes set tolerances too tight without accounting for how the material behaves.
That’s why it’s so important to work with a knowledgeable team early in the design phase. We help customers optimize their models for MJF, saving them time, money, and frustration down the road.”
How can companies get started with HP Jet Fusion at RapidMade?
“It’s simple—just reach out to us for a consultation. We work with businesses at every stage, whether they need design help, prototyping, or full-scale production.
We can review designs, recommend optimizations, and even run test prints to ensure the best possible outcome. If you’re looking for a trusted partner for high-performance 3D printed parts, RapidMade is here to help.
You can email us at [email protected] or visit RapidMade.com to request a quote or schedule a consultation.”
Final Thoughts
“HP Jet Fusion is one of the most powerful and versatile 3D printing technologies available today. When properly optimized, it can rival or even surpass traditional manufacturing in strength, accuracy, and efficiency.
If you want high-quality, production-grade 3D printed parts, reach out to RapidMade—we have the expertise, equipment, and experience to bring your project to life.”
