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[3D Printing Applications] Three Key Differentiators: Laser Sintering VS. Multi Jet Fusion

【3D列印應用】三大重點決勝負：雷射燒結 VS.多射流熔融

3DMART |

【3D Printing Application】Three Key Factors Determine the Winner: Laser Sintering VS. Multi Jet Fusion

Among the three common 3D printing technologies, the movable structures, one-piece molding, and support-free features of powder printing always produce astonishing results. However, there is more than one type of powder 3D printing, and each material offers its own unique advantages!

Taking HP's well-known MJF (Multi Jet Fusion) technology and Sinterit's SLS (Selective Laser Sintering) technology as examples, both are powder-based 3D printing methods, with the main difference being the heating method.
MJF can be seen as a combination of SLS and inkjet technology. Below, we will compare them based on the 3D printing process, molding effect, material characteristics, cost, and speed:

I. 3D Printing Process
A thin layer of powder is evenly spread on the print bed. A laser beam then selectively sinters the powder within the print area. The platform then descends by one layer's thickness, and the powder spreading and laser sintering steps are repeated until printing is complete. After the printer cools down, the compacted powder block can be removed to retrieve the finished product.
 
The first layer of powder is spread on the print bed and heated to a temperature close to sintering. A print head then sprays a fusing agent over the print area, while a detailing agent is sprayed on non-forming areas to prevent edge sintering. Subsequently, infrared light is applied to the powder. The areas sprayed with the fusing agent absorb the heat and fuse to form the object. A new layer of powder is then spread, and the process is repeated until 3D printing is complete. The product also needs to cool down before it can be removed.


II. Molding Effect
Both 3D printing technologies produce parts with a matte finish. MJF parts are typically black because dark fusing agents absorb heat more effectively; SLS parts are often white and easier to dye. Gray SLS nylon powder is also very common, and these materials have a smoother texture than MJF.
 

MJF and SLS are both high-precision industrial technologies that do not require support structures and are suitable for one-time 3D printing of complex movable prototypes. However, MJF generally offers better overall surface finish because the MJF print head sprays fusing agent with 1200 DPI resolution (approximately 0.022mm per unit) at the printing location, whereas the laser spot size of SLS is about 0.3-0.4mm.
 

Additionally, the detailing agent used in non-forming areas in MJF helps to enhance the features and sharp edges of 3D prints. However, MJF is more prone to warping compared to SLS technology.
 
(MJF is suitable for producing intricate structures, such as the sharp protrusions on gear edges, which can be accurately reproduced.)

III. Material Characteristics
The most commonly used powder for both technologies is generally PA 12 (nylon polymer). Since 3D printed objects can exhibit stress differences due to the printing direction, MJF offers better stress uniformity in all directions compared to SLS. However, SLS printers provide a wider range of material options, such as flexible TPU, TPE, PA11, etc., as the technology developed earlier and is more mature.

HP's MJF currently only offers PA materials, and important engineering properties such as high impact resistance and deformation resistance are not yet fully developed. With rapid advancements in technology, we believe more material options will be available in the future.


IV. Cost and Speed
Taking HP's MJF as an example, professional post-processing equipment can significantly speed up cooling and remove excess powder. Additionally, 80-85% of recycled powder can be reused, whereas in SLS, the ratio of old powder to new powder needs to be at least 50%.

Furthermore, MJF technology can print even when the powder chamber is not completely full, while SLS equipment requires the powder chamber to be fully filled for each print. The printing time depends on the number of powder layers, which is the main reason for the speed difference. Therefore, for SLS, accumulating multiple objects and filling the print space as much as possible is the most cost-effective approach.
 
(Taking the bracket model in the figure as an example, with a volume of 23.8 cm3 and dimensions of 101.9 x 45.0 x 18.0 mm, price comparisons are provided for 1, 10, and small-batch production of 100 units.)
 
As shown in the table below, due to MJF's dedicated post-processing and simplified cooling procedures, the 3D printing cost for a single object is lower than that of SLS. However, as the quantity increases, the prices of both technologies become quite similar, as printing multiple SLS parts at once reduces the average cost.


Summary:
．SLS powder sintering uses laser spot curing, while MJF sprays fusing agent and then cures it with infrared light.
．Both MJF and SLS technologies can 3D print high-precision, matte-textured, complex movable parts without supports.
．Currently, SLS offers a diverse range of materials and mature technology, while MJF is slightly faster and has more uniform mechanical stress.
．The cost of small-batch production for both technologies is similar, but for single objects, MJF is cheaper.

Through this sharing, do you have a better understanding of powder 3D printing? 3DMart not only provides 3D printing services, but also offers more equipment and application examples for SLS powder sintering and MJF Multi Jet Fusion technology. Contact us now for more information.

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