HP hosted the third session of its Beyond the Layers of Polymers 3D Printing webinar series on 10 July 2025. While the first two sessions explored customer success stories and introduced the Jet Fusion system’s components, this one shifted focus to the journey ‘from first success to full production.’
Justin Hopkins, application engineer manager at HP, highlighted the progression of HP’s 3D printing systems, the 5000, 5200, and 5600 series, to demonstrate how businesses can transition from initial adoption to scaled manufacturing. Rather than simply presenting features, he illustrated the journey through a case study of a fictitious company, Footright Orthotics, which produces custom insoles. It demonstrated a common entry point for businesses exploring additive manufacturing, starting with modest production volumes and scaling up as demand increases.
“Depending on where or what stage you are within your business, we are going to walk through a journey from the 5000 to the 5600, and show how to right-size your business for the equipment you actually need.”
For companies just beginning, the Jet Fusion 5000 series offers the lowest acquisition cost. The fictitious Footright Orthotics, producing about 50 pairs of insoles per week, represented a typical use case. The 5000 series build capacity—380 x 284 x 250 mm—fits this demand comfortably, requiring just over one build per week.
A key consideration for entry-level users is manual powder management. The 5000 series can be operated with or without a processing station, and customers conscious of overhead may opt for manual management, which involves a multi-step process of extracting, mixing, and loading additive powders. While cost-effective, this requires significant labor. Hopkins noted, “Yes, you are at a lower entry point, but then you have the manual powder management. As your company grows, you can add a processing station to reduce manual labor.”
Users may begin with HP’s 3DOS program, a pay-per-build model with predictable costs and lighten the burden of consumable management. In the example case of Footright Orthotics, one full build could produce 39 pairs of insoles in about eight hours of print time—nearly covering their weekly demand in a single run.
The 5200 Series
As production needs expand, for example, to 200 pairs of insoles a week, the 5000 series becomes stretched to its limits. The Jet Fusion 5200 series allow a build volume of 380 mm (compared to 250 mm on the 5000), enabling larger runs and higher throughput. “The hardware between the two isn’t drastically different,” Hopkins explained. “The main difference is built height and the ability to access additional print modes.”
With the 5200’s capacity, Footright Orthotics could produce 66 pairs per build, completing 200 pairs in just three builds per week rather than five. Workflow optimization also becomes critical at this stage. Features such as natural cooling units and automatic unpacking stations reduce labor costs and improve efficiency, implying that scaling does not necessarily mean adding more staff or printers.
Scaling with the 5600 Series
For companies ready to fully scale, the Jet Fusion 5600 series contains improvements in hardware for repeatability, reliability, and process control. According to Hopkins, “The 5600 has the highest uptime, lowest maintenance costs, and improved thermal management. That translates into higher yields and fewer scrap parts.” According to him, while a 5200 might achieve a 95% yield, the 5600 pushes that figure to 97-98%.
One feature is process development, a software capability for fine adjustments at multiple levels, whether general, by zone, by region, or by individual part. This enables manufacturers to fine-tune jobs for a variety of applications. For example, if Footright Orthotics began contract manufacturing insoles for another brand that prioritized speed over mechanical properties, custom process parameters could be created to optimize for efficiency.
The 5600 also supports automation accessories, allowing automatic changeover between builds. This reduces downtime between jobs, saving as much as 40 minutes per cycle and enabling two full builds within 24 hours without additional shifts. Hopkins indicated that this is not merely convenient but helps in efficient scaling.
Through its example case, HP’s session showed that additive manufacturing adoption can evolve logically – starting at the entry-level, moving into higher-volume production, and ultimately achieving scaled, optimized manufacturing. Each step aligns equipment capacity with business growth, ensuring companies invest in the right solution at the right time. Hopkins ended by pointing out that the key is to align technology with growth. “You don’t want extra capacity you’re not using. The goal is to right-size your business for the applications and equipment you actually need.”
The next session in the 3D webinar series will focus on materials, beginning with PA-12 (Polyamide 12), a thermoplastic material known for its high strength, durability, and chemical resistance used in additive manufacturing.
