HP Jet Fusion

HP Jet Fusion
Name	HP Jet Fusion
Caption	An HP Jet Fusion 5200 Series 3D printer
Manufacturer	HP Inc.
Type	Powder bed fusion
Material	Thermoplastic powders
Year	2016

HP Jet Fusion. It is a line of industrial 3D printing systems developed and manufactured by HP Inc. that utilizes a proprietary form of Multi Jet Fusion technology. The process is distinguished by its use of fusing agents and detailing agents deposited by an array of inkjet printheads to selectively fuse thermoplastic powder layers, enabling high-speed production of functional parts. Since its commercial introduction, it has been positioned as a solution for digital manufacturing and short-run production across various industries, competing with established methods like selective laser sintering.

Technology Overview

The core technology is a powder bed fusion process that operates at the voxel level for precise control. An array of thermal inkjet printheads, similar to those used in HP PageWide technology, moves across a bed of polyamide or other polymer powder. It deposits a fusing agent onto areas meant to be solidified and a detailing agent at the edges to refine part geometry. Following this, an infrared energy source passes over the entire bed, causing the areas with fusing agent to melt and fuse, while the detailing agent inhibits fusion for sharper edges. This layer-by-layer approach allows for the creation of complex lattice structures and consolidated assemblies that would be difficult with injection molding.

Development and History

The technology emerged from research within HP Labs, building upon the company's expertise in inkjet printing and digital manufacturing. It was first unveiled to the public in 2014, with commercial systems launched in 2016 under the leadership of then-CEO Dion Weisler. A significant partnership was formed with BASF to develop new polymer materials, expanding beyond the initial PA 12 nylon. Subsequent hardware generations, like the HP Jet Fusion 5200 Series, introduced in 2018, offered improved color 3D printing capabilities and finer surface finishes. The development has been closely followed by industry analysts at Wohlers Associates.

Materials and Applications

Primary materials include engineering-grade thermoplastics like PA 11, PA 12, and TPU developed with partners like BASF, Evonik Industries, and Lehmann & Voss. These materials enable the production of functional, end-use parts with properties suitable for demanding applications. Key industries adopting the technology include the automotive industry for ductwork and brackets, the healthcare sector for medical devices and orthotics, and consumer goods companies for footwear components and electronic enclosures. The ability to produce graded material properties is also a subject of ongoing research.

Process and Workflow

The workflow is integrated within the HP SmartStream software ecosystem, beginning with 3D data from CAD systems like SolidWorks or Autodesk Inventor. The build process is fully automated, with the printer managing powder heating, agent deposition, and infrared fusing in a cyclical manner. After a build job is complete, the entire powder bed is transferred to a separate processing station where loose powder is removed via vacuum and compressed air, and parts are bead-blasted for final cleaning. Unfused powder is recycled for subsequent builds, aiming for high material reuse rates.

Comparison with Other 3D Printing Methods

Compared to selective laser sintering, a primary competitor in polymer additive manufacturing, it offers significantly faster build speeds due to its area-wide fusing approach rather than point-by-point laser scanning. When contrasted with stereolithography, it produces parts with better isotropic mechanical properties but typically has a rougher surface finish. Unlike fused deposition modeling, it does not require support structures, allowing for more complex geometries. However, the technology generally involves a higher initial system cost than many desktop 3D printers.

Market Impact and Commercial Use

Its introduction signaled HP Inc.'s major entry into the industrial additive manufacturing market, challenging established players like 3D Systems and EOS GmbH. The technology has been adopted for digital warehousing and on-demand manufacturing by service bureaus such as Forecast 3D and Jabil. Major corporations, including BMW, Volkswagen, and Siemens, have integrated it into their prototyping and production pipelines. The system's emphasis on economies of scale in production has influenced the broader industry's shift toward additive manufacturing for end-use parts beyond just rapid prototyping.

Category:3D printing Category:HP Inc. Category:Industrial equipment