Stratasys ToughONE™: Revolutionizing PolyJet 3D Printing for Durable, Functional Prototypes

For many years, Stratasys’ innovative PolyJet technology has stood as the gold standard in 3D printing for visual prototyping. Its ability to produce high-fidelity color models, capture ultra-fine details, and deliver exceptionally smooth surfaces has made it indispensable for designers and engineers focused on aesthetics. However, beneath this highly praised visual excellence lay a well-known limitation within the industry: the inherent fragility of PolyJet materials often prevented their application in rigorous functional testing and real-world end-use applications. This meant that while a prototype might look perfect, it couldn’t reliably withstand the stresses of actual performance evaluation, forcing engineers to often turn to other 3D printing technologies or traditional manufacturing methods for truly functional parts.

With the groundbreaking launch of ToughONE™, Stratasys is fundamentally changing the rules of the game to directly address this critical need. This innovative new material, introduced on June 10th by the leading 3D printing company, represents a significant breakthrough for the entire PolyJet ecosystem. ToughONE™ seamlessly combines the flawless aesthetic capabilities that PolyJet is renowned for – including vibrant colors, intricate details, and smooth finishes – with the robust mechanical strength essential for comprehensive functional prototyping and even the production of durable final parts. This development raises a pivotal question: are we entering a new era where engineers and designers no longer face the difficult choice between impeccable form and superior performance? Stratasys believes ToughONE™ is the answer, ushering in a future where design intent and physical resilience can coexist in a single, streamlined process.

ToughONE™ Takes PolyJet Technology to Unprecedented Levels of Durability

PolyJet technology operates by jetting microscopic droplets of liquid photopolymer resin onto a build tray. These droplets are then instantly cured layer by layer using a UV light source, gradually building up the 3D object. This precise additive manufacturing process is celebrated for its exceptional accuracy and ability to produce models with incredible detail and a wide range of colors and textures.

Historically, while PolyJet technology has been considered the ideal tool for visualizing complex concepts through realistic Pantone® colors, lifelike textures, and intricate geometries, its use has largely been confined to aesthetic or non-functional prototypes. When it came time to subject a component to stress tests, mechanical loads, or environmental conditions, design teams typically had to switch to other 3D printing technologies, such as FDM or SLS, which are known for producing more robust and durable parts. This multi-technology approach, however, often led to significant inefficiencies, including longer lead times, increased manufacturing costs due to multiple setups and material changes, and a more complex workflow. Engineers had to accept a compromise: either beautiful models that couldn’t perform, or strong models that lacked visual realism. This forced separation between form and function created bottlenecks in the product development cycle, hindering rapid iteration and comprehensive testing.

The market introduction of ToughONE™ material definitively eliminates these long-standing trade-offs. Instead of forcing a choice, it offers a revolutionary combination: high impact resistance, exceptional wear resistance, and remarkable toughness, all without sacrificing the characteristic smooth surface finish, unparalleled accuracy, and dimensional stability under various loads and stresses that PolyJet users have come to expect. This means that with ToughONE™, designers and engineers can now seamlessly transition from early-stage aesthetic prototyping to advanced functional prototyping, and even into the realm of final part production for low-volume applications, all within the same machine and technology platform. This singular capability streamlines the entire product development process, enabling unprecedented agility and efficiency.

Exclusively Designed for the J8 Series: Maximizing Performance

A natural question for Stratasys users is: which machines are compatible with this groundbreaking new material? ToughONE™ is currently available exclusively for the Stratasys J8 series, which encompasses the powerful J850™ Prime, the versatile J850™ Pro, and the compact J826™ models. These advanced PolyJet systems are engineered to offer large print volumes, enabling the production of substantial prototypes or multiple parts in a single build. They boast superior Pantone® color matching capabilities, ensuring design intent is accurately translated into physical models, and include advanced features such as Voxel Print™ for precise control over material properties at a microscopic level, and Smart Insert™ for embedding components during printing. All these features are managed through the intuitive and powerful GrabCAD Print Pro™ software, which optimizes the printing process for efficiency and quality.

For organizations currently utilizing earlier PolyJet systems like the J3 or J5 series, the advent of ToughONE™ presents a compelling and significant reason to consider an upgrade. This new material transforms the value proposition of the J8 series, making it an even more powerful asset for comprehensive product development. For new users considering their entry into additive manufacturing, ToughONE™ on a J8 series machine offers an unparalleled opportunity to consolidate their entire workflow onto a single, highly capable platform. By doing so, companies can eliminate the historical need for multiple machines for different stages of development (e.g., one for aesthetics, another for strength), thereby simplifying complex post-processing steps and significantly mitigating risks within the production environment. Users can also unlock a cascade of benefits, including vastly accelerated rapid design iterations through virtually real-time testing of functional prototypes, substantially shorter development cycles from concept to validation, and a notable reduction in time-to-market for new products. Additional tangible advantages include dramatically lower prototyping costs due to fewer external dependencies, fewer production delays caused by material or process changes, and the invaluable confidence to consistently produce critical functional elements such as robust snap-fits, durable living hinges, and secure structural enclosures, all with the high-fidelity aesthetics PolyJet is known for.

Ultimately, the combination of ToughONE™ material and the powerful J8 systems is meticulously designed to empower organizations to innovate with greater speed, intelligence, and overall efficiency. This integrated solution provides a competitive edge in an increasingly fast-paced global market, allowing businesses to bring better products to market faster and with fewer resources.

Expansive Applications of Stratasys’ ToughONE™ Material

One of ToughONE™’s most significant strengths lies in its seamless integration with PolyJet’s inherent multi-material philosophy. The ability to combine up to seven different resins within a single print job unlocks an extraordinary range of possibilities. This unparalleled versatility allows for the creation of prototypes with distinct zones of differentiated mechanical properties, such as a single part featuring both flexible hinges and rigid structural sections. Engineers can now produce complex components capable of accurately simulating real-world conditions of mechanical stress, enabling more comprehensive and reliable testing. Furthermore, it facilitates the efficient production of highly detailed and remarkably durable functional parts in small series, bridging the gap between prototyping and true manufacturing.

The array of applications for ToughONE™ is rapidly expanding across an incredibly broad spectrum of industries. In industrial design, it allows for the creation of highly realistic yet functional prototypes that can be handled, tested, and evaluated without fear of breakage, accelerating ergonomic and user experience validation. For consumer electronics, product developers can now prototype durable enclosures, buttons, and internal components that mimic final product performance, speeding up product launches. The medical field benefits immensely from the ability to create patient-specific anatomical models for surgical planning that are both visually accurate and strong enough for manipulation, or durable tools and fixtures. In the automotive sector, ToughONE™ enables the rapid prototyping of interior components, dashboard elements, and even functional engine bay parts for fit, form, and basic function testing. From consumer goods, where it can be used for robust packaging prototypes or household appliance components, to the packaging industry itself, allowing for the creation of resilient and visually accurate packaging designs that can withstand handling and shipping simulations, ToughONE™ offers transformative potential. Its versatility ensures that industries across the board can leverage the benefits of high-fidelity aesthetics combined with enduring strength.

The launch of ToughONE™ is far more than just a simple material upgrade for Stratasys; it signifies a profound and strategic repositioning of PolyJet technology within the additive manufacturing landscape. It transforms what was primarily a platform designed for visualization into a truly comprehensive product development tool, now capable of accompanying every single stage of the product lifecycle. From the genesis of the initial idea and conceptual design, through the creation of highly functional and durable prototypes for rigorous testing, all the way to the efficient production of finished parts in small series, ToughONE™ empowers PolyJet to be a singular, end-to-end solution.

By significantly reducing the dependence on secondary technologies and the associated complexities, Stratasys is committed to offering companies greater speed, enhanced simplicity, and ultimately, superior competitiveness in their innovation processes. This comprehensive, powerful, and now supremely functional platform ensures that businesses can accelerate their product development cycles, reduce costs, and bring revolutionary products to market faster than ever before. ToughONE™ is not just a material; it’s a catalyst for a more efficient and capable future in 3D printing.

Want to delve deeper into the capabilities of ToughONE™ and explore the full potential of the J8 series? Find more comprehensive information HERE.

*Cover image: A complex part 3D printed using multi-material PolyJet technology, featuring the new ToughONE material, multiple colors, and components with distinct mechanical properties. This demonstrates the versatility and advanced capabilities of the system. All photo credits: Stratasys.