What is the maximum build size for MJF technology?
From an engineering perspective, the “maximum build size” for Multi Jet Fusion (MJF) is not a single fixed number, but a range defined by the specific machine platform and how you plan your nesting strategy. Commercial MJF systems today typically offer build volumes on the order of a few hundred millimeters in X, Y, and Z—large enough for sizable functional housings, brackets, and manifolds, but still smaller than most sheet-metal or casting envelopes. For custom parts projects, we treat MJF as a mid-size production technology that complements processes like CNC machining services and 3D printing rather than replacing them.
Typical MJF build envelope and what it means
Modern MJF machines are designed around a rectangular powder bed. A common industrial configuration features a build area approximately 380 × 280 mm in the X–Y plane, with a Z height of around 380 mm. When you translate this into usable design constraints, assume that the largest single part dimension should be slightly smaller than the nominal build dimensions to account for powder overflow, edge effects, and process tolerances.
In practical terms, this means that single-piece parts, up to several hundred millimeters in size—such as mid-size enclosures, ducting, or structural brackets—can be printed in one shot. For bigger products, we design modular architectures with interlocking features, then join them post-printing through mechanical fasteners, bonding, or by integrating machining steps via CNC machining prototyping to achieve precise interfaces.
Nesting strategy and effective build utilization
While the maximum build volume is defined by hardware, your effective output depends heavily on how efficiently you nest parts. MJF allows 3D stacking of components in the powder bed, so shorter parts can be packed in layers along the Z direction. For small and medium-sized custom components, we often fill the build with dozens or even hundreds of parts, optimizing orientation to balance dimensional accuracy, surface quality, and packing density.
Here, it is useful to distinguish between prototype builds and serial runs. For prototypes and one-offs, we may prioritize easier depowdering and inspection, leaving more space around parts. For low volume manufacturing or MJF 3D production parts, we move toward higher packing densities and more standardized orientations, then use validated compensation factors to maintain dimensional control across the stack.
When to choose MJF vs. other technologies
If your design fits comfortably within the typical MJF build envelope and is suited to polymer materials (often PA12 or similar engineering plastics), MJF is extremely efficient for functional prototypes and end-use parts. For components that exceed the build size in one dimension, we consider segmenting the design or switching to alternative processes like SLS 3D printed parts, FDM 3D printing solutions, or conventional plastic CNC machining depending on mechanical and cost targets.
For mission-critical industries such as industrial equipment or consumer products, we often utilize MJF to create complex internal features and lightweight structures that would be challenging to machine, and then add tight-tolerance features via CNC machining. This hybrid approach allows you to fully exploit the build volume for complex shapes while still meeting assembly requirements and quality standards.
Design guidelines to make the most of the build volume
To leverage the maximum build size effectively, keep a few practical guidelines in mind:
Target your largest part dimension to be at least 10–20 mm smaller than the nominal machine axis travel to account for margins and tolerance.
Use modular designs for very long or wide parts and plan joining methods upfront.
Orient parts to minimize warpage and critical dimension distortion, not just to “fit” them into the box.
For production runs, standardize orientations and nesting patterns so that mechanical properties and dimensions are repeatable from build to build.
Combine MJF with secondary operations such as one stop service including machining and finishing when you need high-precision interfaces or aesthetic surfaces.
In summary, the maximum build size of MJF defines a generous but finite design envelope for single parts, while clever nesting and hybrid processing let you scale from prototypes to production within that same volume.
