HP has launched a webinar series titled ‘Beyond the Layers — A Polymers 3D Printing Series,’ designed specifically for engineers, designers, and manufacturing professionals looking to explore real-world applications of HP’s 3D printing technologies.
The series, the company says, aims to provide an understanding of HP’s Jet Fusion 3D Printing technology, going beyond basic concepts to explore advanced use cases, production workflows, and the technicalities of the process.
The inaugural session, held on 29 May 2025, took the attendees through the entire workflow of HP’s Jet Fusion technology. Hosted by Caton Medellin from HP, the session offered an in-depth look at how the Multi Jet Fusion (MJF) process works and showcased how it’s being applied across diverse industries, from healthcare and automotive to consumer goods and drone manufacturing.
Caton Medellin began by introducing the core capabilities of the Jet Fusion 3D printer and elaborating on its versatility. “HP’s Multi Jet Fusion technology is reshaping workflows across sectors. From creating highly customized medical devices to producing durable, lightweight automotive parts, the applications are wide-ranging,” Medellin said.
One of the case studies shared during the webinar was that of the Hanger Clinic in the United States. Originally starting with just a single HP 3D printer, the clinic has scaled its operations to a fleet of machines, using them to manufacture ankle-foot orthoses. These customized medical devices are designed based on individual patient scans, offering enhanced comfort, improved treatment efficacy, and significantly reduced production costs. The clinic has further expanded into the development of cranial orthoses, benefiting from the precision and flexibility offered by 3D printing.
Another example was from the automotive customization. Blazin’ Rodz, a California-based custom car shop, integrated Multi Jet Fusion parts into their showpiece vehicle, ‘The Doughboy,’ which went on to win the Best Car Award at the prestigious SEMA automotive trade show. “HP’s Multi Jet Fusion printing is a game-changer for the entire industry,” said Waylon Jeffrey, 3D Design and engineering lead at Blazin’ Rodz. “We are committed to discovering innovative applications with every signature part and every custom car we build moving forward.”
The Eye Alone Project in Africa represents another unique implementation of Jet Fusion 3D printing. This initiative uses drones to help combat wildlife poaching. Medellin highlighted how Multi Jet Fusion enables the production of durable, repairable, and cost-effective drone parts, critical features for devices that operate in rugged, remote environments.
To give viewers a better understanding of how the technology works, Medellin discussed the technical process of Jet Fusion printing. Starting with a cross-sectional view of the build volume, he explained how each layer is formed in a thermal environment. Overhead lamps heat the powder bed to the necessary processing temperature. Fusion and detailing agents are then selectively deposited to shape the part, after which the recoater spreads a fresh layer of polymer powder.
Once the build is complete, the part undergoes a cooling phase. Medellin described two types of cooling: natural and fast. Natural cooling, which takes approximately 30 hours, is well-suited for continuous production. In contrast, fast cooling in the processing station shortens this phase to just over 11 hours, making it ideal for parts with precise dimensional requirements.
The future sessions will offer a deeper dive into the technical components powering HP’s Jet Fusion technology. Topics will include a detailed look at material properties, machine architecture, and a breakdown of the full production process.
