Ultimate HP Jet Fusion 3D Printer Design Guide


This comprehensive guide, derived from HP white papers, transforms essential content into an accessible format for Rapidmade customers. As prominent users of HP technology, ensuring you harness the full potential of the HP Jet Fusion 3D printer is crucial to achieving optimal 3D parts.

Table of Contents:

  1. Best MJF Design Practices

  2. Design for 3D Print Accuracy

  3. Design for Aesthetics / Best Surface Finish on your 3D Prints

  4. Design for Cleaning Jet Fusion Parts

  5. Dimensional Tolerancing 3D Prints

  6. Design for MJF Fit

  7. Design MJF Threads

  8. Design for Threaded Inserts in 3D Printed Nylon

  9. Design Split and Adhesive Bonded 3D Prints

  10. Design 3D Printed Snap Fits

  11. Recommended 3D CAD File Formats and Resolutions

1. Best MJF Design Practices:


Follow recommendations for designing with HP Multi Jet Fusion technology to ensure precise and accurate 3D printed parts.

  • Recommended Wall Thickness: Maintain a minimum wall thickness of 0.3 mm for XY-oriented short walls and 0.5 mm for Z-oriented short walls.

  • Cantilevers: Adjust minimum wall thickness based on aspect ratio for cantilevers, considering width and length.

  • Connecting Parts: Maintain a minimum gap of 0.4 mm for correct assembly between paired printed parts.

  • Moving Parts: Ensure a minimum spacing of 0.7 mm between the faces of printed assemblies.

  • Thin and Long Parts: Implement strategies to minimize warpage, such as adjusting wall thickness, avoiding ridges on flat areas, and incorporating internal lattices.

  • 3D Print Design Optimization Strategies: Explore topology-optimized designs and lattice structures for improved dimensional accuracy, reduced weight, and cost-effective production.

  • Hollow Parts: Optimize design with hollowing while considering a minimum wall thickness of 2 mm for enhanced mechanical properties.

2. Design for 3D Print Accuracy:


Maximize accuracy with HP Multi Jet Fusion technology by adhering to specifications for dimensional accuracy and features like embossed details.

  • Dimensional Accuracy: Achieve IT Grade 13 accuracy with Cpk values comparable to plastic injection molding.

  • Minimum Specifications: Ensure embossed and engraved details have a depth or height of at least 1 mm for optimal output.

3. Design for Aesthetics / Best Surface Finish on your 3D Prints:


Enhance the part appearance and material properties by considering layer lines and geometrical features during the design phase.

  • 3D Print Layer Lines: Minimize the “Stair-Stepping Effect” by optimizing angles between features and the XY plane.

  • MJF Aesthetics Guidelines: Place critical features in the same plane, design smooth cross-section transitions, and consider internal lattices for lighter designs.

4. Design for Cleaning Jet Fusion Parts:


Optimize part cleaning processes with HP Multi Jet Fusion technology, emphasizing the importance of drain holes and design considerations for lattice structures.

  • Drain Holes: Add at least two 5 mm diameter drain holes in hollow parts for efficient powder removal.

  • Lattice Structures: Address challenges in removing trapped powder in lattice structures by leaving the lattice partially open.

5. Dimensional Tolerancing 3D Prints:


Explore dimensional tolerances for parts designed for assembly, considering International Tolerance (IT) Grades and process capability.

  • International Tolerance (IT) Grades: Design parts with appropriate tolerances based on ISO 286/ANSI B4.2-1978 standards.

  • Process Capability: Understand process capability using Cpk values and their correlation with part yield.

  • HP Jet Fusion 3D Process Control: Leverage in-printer features for applying dimensional profiles and achieving manufacturing-level accuracy.

6. Design for MJF Fit:


Optimize mating parts for functional assemblies by selecting suitable fits based on clearance and interference.

  • Fits: Differentiate between clearance and interference fits and select appropriate fits based on the assembly’s functional needs.

  • Standard Fits: Consider international standards (ISO 286, ANSI B4.2, ANSI B4.1) for allowable tolerance limits.

7. Design MJF Threads:


Leverage HP Multi Jet Fusion technology for printing threads, understanding recommendations for self-tapping screws, machined threads, and standard printed threads.

  • Self-Tapping Screws: When dealing with small threads (up to 6 mm), use self-tapping screws for optimal results.

  • Machined Threads: Consider machining threads for small sizes and follow recommended tools for machining HP Multi Jet Fusion parts.

  • Jet Fusion Thread Guidelines: Follow guidelines for designing threads larger than 6 mm under international standards, considering tolerances relative to diameter and pitch.


This guide equips Rapidmade customers with an extensive resource to harness the capabilities of HP Jet Fusion 3D printing technology effectively. Whether addressing design precision, aesthetic considerations, or functional fits, adherence to these best practices ensures optimal outcomes in 3D part production.