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Accuracy and Powder Removal Limits in Multi Jet Fusion 3D Printing.

Karel Raz1, Zdenek Chval1, Petra Faitova1

  • 1Faculty of Mechanical Engineering, Regional Technological Institute, University of West Bohemia, Univerzitni 2732/8, 301 00 Plzen, Czech Republic.

Polymers
|October 28, 2025
PubMed
Summary
This summary is machine-generated.

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Multi Jet Fusion (MJF) printing shows parts in the center have lower accuracy due to thermal variations. Powder removal from lattice structures is limited by density, with low-density lattices allowing deeper cleaning.

Area of Science:

  • Additive Manufacturing
  • Materials Science
  • Mechanical Engineering

Background:

  • Multi Jet Fusion (MJF) is a key 3D printing technology for functional polymer parts.
  • Challenges remain in achieving high dimensional accuracy and effective powder removal from complex internal geometries in MJF parts.

Purpose of the Study:

  • To investigate the spatial variation in dimensional accuracy of MJF-printed parts.
  • To quantify the limitations of unfused powder removal from internal lattice structures in MJF.

Main Methods:

  • Produced 45 PA12 specimens on an HP MJF 4200 printer to map dimensional accuracy across the build volume.
  • Quantified powder removal limits in body-centered cubic (BCC) lattice structures using sandblasting and X-ray inspection.
Keywords:
3D printingMJFaccuracylatticenylon

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Main Results:

  • Parts in the central build area showed poorer dimensional accuracy compared to those at the perimeter.
  • A strong inverse relationship exists between lattice relative density and cleanable thickness; low-density lattices (ρ = 0.07) allowed cleaning up to five layers, while high-density lattices (ρ = 0.39-0.47) were limited to 1.5-1.7 layers.

Conclusions:

  • Non-uniform thermal control influences dimensional accuracy in MJF, with central parts being less accurate.
  • Part placement and lattice design (relative density) are critical for successful powder removal in MJF applications.