Polymer Additive Manufacturing Technologies: Expert Guide & Comparison

Published on July 7, 2022

Originally published on fastradius.com on July 7, 2022

Choosing the right additive manufacturing process can be daunting, given the breadth of available technologies and the variety of materials they can work with. Our engineering team has distilled this complexity into a set of concise, data‑rich charts that highlight the strengths, limitations, and ideal use‑cases for each polymer AM method.

Below you’ll find a high‑level comparison of the following categories:

• Vat polymerization: stereolithography (SLA) and Carbon® Digital Light Synthesis™ (DLS)
• Powder bed fusion: selective laser sintering (SLS) and HP Multi‑Jet Fusion (MJF)
• Material extrusion, material jetting, and binder jetting

Scroll further to explore the specific capabilities of each technology, including resolution, build speed, material compatibility, and post‑processing requirements.

Vat Polymerization – SLA & Carbon® DLS

Vat‑polymerization processes use a liquid resin that is selectively cured by light. SLA offers micron‑level detail and excellent surface finish, making it ideal for functional prototypes, medical devices, and intricate tooling. Carbon® DLS provides the same precision with the added benefit of full‑color output and rapid cycle times.

Powder Bed Fusion – SLS & HP MJF

SLS melts polymer powder layer by layer, enabling the production of robust, mechanically strong parts without the need for support structures. HP MJF further accelerates build speed by using inkjet‑style deposition of binders and photoinitiators, delivering high‑volume, low‑cost components for end‑use applications.

Material Extrusion, Jetting & Binder Jetting

Material extrusion (e.g., FDM) remains the most widely adopted AM technique for rapid prototyping and low‑volume production. Material jetting delivers sub‑millimeter accuracy and smooth surfaces, while binder jetting offers large‑scale, cost‑effective builds, especially for metal‑filled polymers.

Need help selecting the best technology for your application? Contact our engineering experts or log in to your SyBridge Technologies account to compare manufacturability, costs, and lead times across platforms.

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