PolyJet 3D Printing is a powerful printing technology that can create parts with the features of rubber, hard plastic, etc. This printing technology is commonly used for cosmetic prototypes; however, it is also used in creating end-use parts for certain applications. While designing for Polyjet 3D printing, one need to consider certain factors. The below guidelines will help you understand the best practices to design parts with Polyjet 3D Printing Services. With the guidelines, from the expert plastic mould manufacturer, you can ensure that the parts are printed correctly for the job you want them to perform.
PolyJet, just like FDM printing, requires a model to be split into very thin cross-sectional layers before the printing starts. The printer can use this layer as a guide to building the design layer by layer. Once the printer's control software is done with the slicing, your design gets ready to print. After this process, the liquid photopolymers are deposited into the build platform by the print head. The print head has an array of small holes through which the material is deposited. Once a slice is created, a UV light is passed over to cure and solidify the materials. This method will be repeated until the part is completed.
To get the best design for PolyJet, one should consider the physical printers' limitations and specification. Here are certain things that are important in creating a design for PolyJet.
PolyJet printers build volume is 7.9’’x19.3"x15.4". which is the maximum size of a thing the printer can create at once. If the designs are bigger than these dimensions, the best way would be to divide them into sections, print them separately, and glue them together after the entire process.
The Polyjet printers have two-layer height choices, which are .001 and .0006. For the designs with textured surfaces or small features, the best option would be the layer height of 0.0006. However, for most of the other parts, the printers standard layer setting would be enough.
Considering tolerance is quite important when you create designs with any 3D printers. The base tolerance of PolyJet printers for the first- inch printing is ±0.005, and for every additional inch, ±0.001 will be added.
PolyJet 3D printers only put solid infill on parts, making the resulting part stronger than any other infill type. If you need a different infill type, the best option would be to add it to CAD manually.
With PolyJet, you can print two different types of materials that have different degrees of hardness. However, it is important to ensure that the design file should be modified for using a different combination of the same design. A separate STL file should be saved for each different material. For example, designs that use hard plastic and a soft rubber would require two different STL files. By keeping these files, the printers can properly manufacture the designs as per your desire.
Here are the feature recommendations when you plan to create a design for PolyJet.
Wall thickness depends mainly on the type of material you plan to use to 3D print. The recommended smallest wall thickness is between 0.04" and 0.06." The latter is considered the best choice for most of the PolyJet projects. You must be aware that the product could be fragile if you use small wall thickness. So it would be best to consider the right wall thickness for your product's future use.
With any hole, ensure a correct fit with the fasteners or pins you use. For PolyJet 3D printing, the best option would be oversizing the hole or under-sizing the pin by 0.005" that can ensure clearance. Due to tolerance stacking, it is recommended to consider a higher clearance for larger parts. The design of the pins highly depends on the product's future use. Instead of fragile small pins, you can use thick pins to allow more strength and stability in the product and help with reliability and longevity. To enjoy the best results understand the strength type your products need to complete their function.