Biocompatible Materials in 3D Printing: Can MJF Be Used in Medicine?

3D printing has evolved far beyond its original use for rapid prototyping and is now widely applied in medical-grade 3D printing. This technology enables the creation of surgical guides, anatomical models, aligners, orthopedic devices, and fully functional patient-specific prosthetics. For such applications, biocompatible materials, precision, and scalability are essential.

Among the most promising solutions is HP MJF technology for medical devices, developed by Hewlett-Packard. Thanks to the use of PA 12, it delivers high productivity, dimensional accuracy, and verified biocompatibility.

In this article, we explore MJF for medical applications, identify the use cases where it excels, and highlight the critical regulatory, technical, and production considerations.

What Is Biocompatibility and Which Standards Apply?

In medicine, not all materials are suitable for every type of human contact. The biocompatibility of a material depends on the type and duration of exposure. The ISO 10993 standard series is used for biological evaluation of medical devices.

For PA 12 biocompatibility in MJF printing, the following standards are key:

• ISO 10993-5 — Cytotoxicity testing (impact on living cells)
• ISO 10993-10 — Assessment of sensitization and irritation
• ISO 10993-11 — Systemic toxicity
• ISO 10993-12 — Sample preparation and reference materials
• ISO 10993-18 — Chemical characterization of materials

HP’s PA 12 has successfully passed the fundamental stages of biocompatibility testing, including confirmed hypoallergenic properties.

Where Are the Boundaries of MJF in Medicine?

PA 12 is resistant to moisture, UV, chemicals, and extreme temperatures, making it ideal for dentistry, orthopedics, and surgical modeling. But some nuances must be addressed during design and manufacturing.

As examples, not all MJF-printed parts can withstand autoclave sterilization (above 120°C), and thin walls (under 1.5 mm) are prone to deformation. In the first instance, alternative sterilizable 3D printing methods such as gas (ETO) or plasma sterilization are preferred, while forthin walls, extended overhangs, and narrow channels, strength calculations and validation testing would be required.Moreover, MJF for medical use must involve clean production environments, traceability of materials, and compliance with MDR (EU) or FDA (US) regulations.

Case Studies: MJF in Medical Practice

Makerly, a company specializing in industrial 3D printing, regularly completes projects for medical institutions and equipment manufacturers. Here are two examples of how MJF 3D printing for biocompatible parts solves real-world challenges.

Case 1: Anatomical Hip Joint Model

ABV-Stroy, a 3D printing studio operating since 2014, was approached by a medical institution requesting the production of an anatomical model of the hip joint. The model was intended for surgical planning, allowing doctors to study the specific anatomy of the affected area in advance. The project required high detail resolution, a smooth surface finish, and fast turnaround.

ABV-Stroy handed the project over to Makerly. Within five days, our specialists produced the model using an HP Jet Fusion 5210 system and HP PA 12 material. The result was a precise part with clean geometric contours and no visible layering. The model was not only suitable for visual study but was also able to withstand mechanical stress: doctors mounted metal fixators and performed practice drilling on it. Such durable parts are difficult—if not impossible—to produce using other technologies like FDM.

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Case 2: Series of Jaw Models for Aligners

Orthos Clinic, specializing in the production of aligners, faced a sharp increase in order volume. Treating a single patient required printing up to 60 unique jaw models. The existing equipment couldn’t handle the workload: the Stratasys printer provided the necessary quality but couldn’t meet the required quantity of orders.

To solve this challenge, the clinic turned to Makerly. Our team set up serial production using the HP Jet Fusion 5210 system and PA 12 material — part of the advanced HP MJF technology for medical devices. We delivered up to 400 models per week, reaching a total of 1,500 parts per month. Thanks to Multi Jet Fusion technology and the properties of PA 12, we achieved high geometric accuracy, smooth surfaces, and full biocompatibility. As a result, Makerly helped the clinic produce the necessary amount of orthodontic aligners with the required characteristics.

This level of production speed and consistency allowed the clinic to scale its business without compromising treatment quality or missing delivery deadlines for patients.

Why MJF Is Ideal for Medical Applications

Compared to FDM or some SLS systems, MJF offers a scalable and efficient cycle:

• The preparation stage includes slicing the models and arranging them within the build chamber.
• The actual printing process takes between 8 and 12 hours, depending on the volume.
• Cooling lasts approximately 24 hours, ensuring a uniform temperature drop.
• Powder removal is done mechanically and requires no solvents.
• Most parts do not require post-processing — sandblasting is usually sufficient.

This technology eliminates the need for support structures — parts can be nested tightly, saving build space. Surfaces come out smooth and stair‑free, with high dimensional stability. Unlike SLA or FDM, where quality depends on print orientation, MJF delivers uniform properties across all axes.

Additionally, PA 12 outperforms comparable materials in deformation resistance, and the ability to reuse leftover powder makes the process both environmentally friendly and cost-effective.

MJF 3D printing is a mature industrial solution that is now being used in medicine. The technology enables the production of precise, safe, and individualized parts — from bone models to orthodontic components. Thanks to its high speed, consistency, and the successful biocompatibility testing of MJF materials, it supports both one‑off and series production that meets the real‑world requirements of doctors and patients alike.

In the coming years, we can expect the emergence of new certified materials for long-term contact, an expanded range of sterile solutions, and the introduction of full-color and multi-material printing. This will enable the use of MJF not only in laboratories but also directly in clinical settings—as part of a fully digital, fast, and personalized approach to medicine.