Circular economy: how MJF fits into the concept of sustainable manufacturing

The climate crisis, resource scarcity, and growing public pressure are forcing companies to rethink traditional manufacturing approaches.

Businesses are increasingly moving away from an outdated linear model in which resources are extracted, converted into products, and then sent to landfill after use. This process is especially inefficient when working with materials that are difficult to recycle – for example, plastics or nickel-based alloys.

The alternative is a circular economy, where waste is not destroyed but becomes a resource for a new cycle.

This model naturally aligns with Multi Jet Fusion (MJF) – HP’s modern industrial 3D printing method. The technology is not only cost-effective and flexible, but also supports businesses by helping their production become more responsible: adopting sustainable manufacturing MJF processes reduces waste and lowers emissions..

From a linear model to a digital cycle

Consider the production of a plastic enclosure using injection moulding. To manufacture a part, a mould has to be made – expensive, bulky, and inflexible. And if the design of the part changes, the mould becomes waste. Plastic residues generated during the process are also often impossible to reuse. The result is tonnes of waste, a long lead time, and limited flexibility.

MJF works differently. It enables on-demand production without moulds and without excess stock. Most importantly, the majority of powder that is not used during printing can be reused, supporting material reuse and recycled powders 3D printing.

MJF as a green 3D printing technology for responsible manufacturing

Unlike many other technologies, MJF enables a high packing density of parts in the build chamber. The tighter the packing, the less energy is required to produce each part, which improves energy efficiency and makes the process resource-efficient manufacturing. This approach reduces not only material consumption but also overall energy use per unit of output, supporting additive manufacturing sustainability.

After printing, around 70–80% of the processed powder can be reused. The remainder is topped up with fresh material, and the cycle starts again. This creates an almost closed-loop production model, which fits perfectly with the principles of the circular economy. Moreover, waste reduction with MJF and the powder reuse rate is significantly higher than in traditional powder-bed methods such as SLS, enabling eco-friendly MJF production.

After parts are removed, most of the powder is reused. Finished products require minimal post-processing

Another advantage of the technology is the absence of support structures and the ability to produce parts with no post-processing. With MJF, additional supports are not required in the way they are for FDM printing. Parts are printed ready for use or require only minimal finishing.

Manufacturing at Makerly is carried out in accordance with ISO 9001 and ISO 14001 requirements, which guarantees high product quality and environmental responsibility across all processes.

Safe and certified materials

Makerly uses certified materials for printing: PA 12, PA 12 W, PA 12 S, and flexible polyurethane TPU. These are safe and contain no toxic components. In addition, PA 12 complies with ISO 10993, which confirms its biocompatibility. This is especially important for medical and consumer products and for recyclable materials in regulated applications.

TPU is widely used not only for prototypes but also for serial products. The flexibility and wear resistance of this material make it an optimal choice for orthopaedic products, cushioning inserts, flexible housings, and other functional components in healthcare, engineering, and light industry.

MJF makes it possible to reduce reliance on toxic coatings and alloys, supporting reduced nickel dependency. In traditional manufacturing, nickel and heavy metals are used to increase strength or wear resistance, but these substances are difficult to dispose of and create toxic waste. MJF uses clean, neutral materials that are safe for both people and the ecosystem.

How MJF helps businesses meet sustainability requirements

Sustainable manufacturing is not only about the environment. Modern standards require companies to consider three areas: environmental impact, social responsibility, and governance of processes. MJF helps businesses meet all three aspects and supports a sustainable supply chain.

Environment: local 3D printing reduces waste volumes, lowers the need for transport, and enables carbon footprint reduction. This approach makes production more eco-friendly and sustainable.

Social dimension: the technology enables rapid production of medical and personalised products that are precisely adapted to a specific user. This increases accessibility, helps people receive what they need without long waiting times, and directly improves quality of life.

Governance system: digitalisation of manufacturing processes enables batch traceability, the use of digital libraries, and consistent standards. This simplifies quality control and makes the supply chain transparent, predictable, and manageable.

In this way, MJF helps companies deliver all three ESG aspects, not in theory, but in practice, through MJF sustainable solutions and responsible manufacturing.

More than just a trend, the circular economy is now becoming a new norm that businesses must adapt to. MJF helps companies take this path smoothly: with minimal investment, no long cycles, reduced waste, and maximum adaptation to a specific demand.

This is not just a move away from overproduction and warehousing costs. The MJF model enables a faster response to demand and reduces risks associated with market changes. For companies focused on sustainability, this option provides a significant strategic advantage.