Integrating MJF into Existing Production: Where to Start and How to Avoid Common Mistakes

The industry is increasingly shifting towards flexible technologies, while companies meanwhile are aiming to reduce time-to-market, lower costs, and respond more quickly to customer demands. This is where additive manufacturing comes into play — in particular, Multi Jet Fusion (MJF) technology from Hewlett Packard. MJF enables companies to achieve process optimization, launching production in just a few days instead of two months, and without the need for costly injection molds.

At a time of industry transition, more and more companies are adopting flexible technologies to speed up product launches, cut production expenses, and respond rapidly to the needs of their customers. 

One of the most effective tools for manufacturing efficiency is on-demand industrial 3D printing, and by partnering with Makerly, you can produce parts using HP’s Multi Jet Fusion (MJF) technology in just a few days — no mold orders or production line changes required. We handle the entire process: from 3D model validation to post-processing and final quality control.

However, adopting a new technology requires a thoughtful approach. Without understanding its specifics, material usage, and preparing properly, you risk delays, defects, and an inefficient use of budget. 

In this article, we’ll explore where to start with MJF, how to avoid common mistakes, and what real-world benefits the technology can offer.

What is MJF and What Makes This Technology Unique

MJF (Multi Jet Fusion) is a powder-based 3D printing technology where a fusing agent is applied to a layer of polyamide powder, and then the layers are fused using infrared light. This process ensures high accuracy, uniform strength, and minimal post-processing.

Unlike FDM, which builds parts layer by layer using thermoplastic filament, or SLS, which uses a laser to sinter powder, MJF does not require support structures, delivers more consistent quality throughout the build, and is ideal for both low- and mid-volume production.

Rapid Product Launch and Iterative Development

One of MJF’s key advantages is the ability to quickly develop and improve a product at every stage. This approach is especially valuable for projects where a hypothesis needs to be tested, design modifications made, and a working prototype produced. Such flexibility is often unattainable in traditional manufacturing — tooling can take weeks and severely impact production speed, while design changes require significant time and cost.With MJF, you can receive the required parts within 3–7 business days. This allows developers and engineers to gather feedback, modify geometry, and relaunch production — all within a single week. This speed is critical for startups, product teams, and R&D departments. The technology is also well-suited for companies that need to personalize products without sacrificing production scalability.

Where to Start: A Detailed Plan for Integrating MJF

Integrating MJF into an existing production workflow requires a step-by-step approach. Below is a recommended framework to follow.

Define your goals.
Why do you need 3D printing — for fast prototyping, small-batch production, replacing injection molding, or rapid product adaptation? The strategy depends on your answer.

Analyze your requirements.
If impact resistance is important, consider the load conditions, operating environment, and tolerances. If biocompatibility is critical, select a suitable material. HP PA 12 — the most commonly used material in MJF — combines strength, moisture resistance, and skin safety.

Prepare the model.
Many issues arise at this stage. To avoid them, adapt your 3D model to the specifics of the technology: avoid overly thin walls (minimum thickness — 0.7 mm), leave at least 0.5 mm gaps between parts, and account for shrinkage and part orientation. Any geometric errors may lead to warping or failed prints.

Refine print parameters:
This includes fill density, part positioning in the build chamber, and grouping items into a single print cycle. Incorrect orientation can lead to deformation, excessive material use, or reprints.

Plan for post-processing.
Will sandblasting, coloring, sealing, or assembly be required? A clear understanding of post-printing steps saves both time and resources.Set up a quality control system.
A quality control system should include tolerance checks, visual inspection, and tests for strength or sealing. It’s essential to define in advance how parts will be evaluated for compliance with technical requirements.

Common Mistakes When Implementing MJF

Even with a well-structured plan, you may still face challenges. Common issues include importing unprepared models, incorrect orientation during printing, and underestimating the importance of post-processing. Many also fail to account for the material’s shrinkage, which can result in final part dimensions not matching the original drawings.

To avoid these pitfalls, it’s important to discuss in advance:

— Whether the geometry needs to be reinforced or adapted for MJF
— What kind of post-processing the parts will undergo
— In what conditions the parts will be used and which properties are critical

The clearer the requirements are at the start, the less likely the final product will fall short of expectations.

How MJF Helps in Practice

To illustrate how this technology supports rapid production, low-volume manufacturing, and cost optimization, here are two real-world examples from Makerly.

Case 1: Custom Knife Handle Scales
The client — a private maker of handcrafted knives — needed 20 sets of handle scales, each weighing 13 grams. Key requirements were accuracy, impact resistance, and water resistance. FDM printing failed to deliver the needed quality due to a weak layered structure. Injection molding was not cost-effective.

Before printing, the model was refined: corners were reinforced, the geometry was adjusted for even powder fusion, and smoother transitions were added. Printing was done using the HP Jet Fusion 5210, followed by sandblasting and coloring. Within five days, the customer received ready-to-use parts.

Case 2:  Headphone Housings for the PigPug Startup
PigPug develops EEG headphones for children with ADHD and ASD. The parts needed to be strong, lightweight, and uniquely shaped for each child. Skin-safe material was also essential. FDM did not deliver the necessary precision and surface quality. Injection molding was excluded due to high costs and limited flexibility.

The team submitted the models to Makerly. We first printed a test batch, then adjusted the fit and geometry. Once the final version was approved, Makerly produced four complete sets with full finishing and coloring. The entire process took five business days, including all of the design iteration.

Top 5 Key Points to Consider When Adopting MJF

• MJF allows you to produce parts with end-use quality without molds or lengthy setup.
• It’s ideal for low-volume production, complex geometries, and product customization.
• Proper model preparation is critical for achieving accuracy and consistency.
• Even experienced manufacturers can make mistakes in part orientation and parameter selection — knowing the technology is essential.
• With smart integration, MJF can save several weeks in time-to-market and reduce small-batch production costs by 2–3x.

MJF is a technology that makes manufacturing faster and more flexible.
It helps companies launch products in just a few days, iterate designs quickly, produce small batches without tooling, and enable personalization at no extra cost.

Time savings, design freedom, cost reduction, and adaptability to customer needs — these advantages make MJF a powerful tool for modern industrial manufacturing.