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Compare 3D Printing Technologies
Side-by-side comparison of FDM, SLA, SLS, MJF, DMLS, and PolyJet to help you select the right technology for your project requirements, budget, and timeline.
Technology Specifications at a Glance
Compare key performance metrics across all six 3D printing technologies available at IamRapid.
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| Specification | FDMFused Deposition Modeling | SLAStereolithography | SLSSelective Laser Sintering | MJFMulti Jet Fusion | DMLSDirect Metal Laser Sintering | PolyJetPhotopolymer Jetting |
|---|---|---|---|---|---|---|
| Accuracy / Tolerance | ± 0.5 mm | ± 0.1 mm | ± 0.3 mm | ± 0.2 mm | ± 0.1 mm | ± 0.1 mm |
| Min Wall Thickness | 0.8 mm | 0.5 mm | 0.7 mm | 0.5 mm | 0.4 mm | 0.6 mm |
| Max Build Volume | 900 x 600 x 900 mm | 335 x 200 x 300 mm | 340 x 340 x 600 mm | 380 x 284 x 380 mm | 250 x 250 x 325 mm | 490 x 390 x 200 mm |
| Surface Finish (Ra) | 15 - 25 μm | 2 - 4 μm | 8 - 12 μm | 6 - 10 μm | 8 - 15 μm | 1 - 2 μm |
| Layer Height Range | 50 - 400 μm | 25 - 100 μm | 80 - 120 μm | 80 μm | 20 - 60 μm | 16 - 32 μm |
| Material Options | 15+ (PLA, ABS, PETG, Nylon, TPU, etc.) | 12+ (Standard, Tough, Flexible, Castable Resins) | 5+ (PA12, PA11, Glass-filled Nylon) | 3+ (PA12, PA12GB, PA11) | 4+ (Aluminium, Titanium, Stainless Steel) | 6+ (Vero, Tango, Agilus, Digital ABS) |
| Typical Lead Time | 2 - 3 days | 2 - 4 days | 3 - 5 days | 3 - 5 days | 5 - 10 days | 3 - 5 days |
| Price Range | Low | Medium | Medium | Medium | High | High |
| Best For | Rapid prototyping, functional testing, jigs & fixtures | Detailed visual models, jewellery masters, dental models | Functional parts, batch production, complex geometries | Production-grade parts, consistent batches, snap-fits | Metal prototypes, aerospace components, tooling inserts | Multi-material prototypes, overmoulding simulation, visual models |
Which Technology Should You Choose?
Match your project requirements to the right 3D printing process. Here are the most common scenarios and our recommendations.
Rapid Prototyping on a Budget
FDM
Also: SLA
FDM offers the fastest turnaround and lowest cost per part. Ideal for form-fit testing and iterative design cycles where fine surface detail is secondary to speed and affordability.
High-Detail Visual Prototypes
SLA
Also: PolyJet
SLA produces highly detailed parts with smooth surfaces, making it ideal for presentation models, master patterns for casting, and applications requiring fine feature resolution down to 0.1 mm.
Functional End-Use Parts (Plastic)
MJF
Also: SLS
MJF produces nylon parts with consistent isotropic mechanical properties, making them suitable for functional end-use applications. SLS is an excellent alternative with broader material options.
Low-to-Mid Volume Production
MJF
Also: SLS
Both MJF and SLS are support-free powder bed processes that allow dense nesting of parts, making them cost-effective for batch production runs of 50 to 5,000+ units.
Metal Parts and Components
DMLS
DMLS is the only metal 3D printing technology in our offering. It produces fully dense metal parts in aluminium, titanium, and stainless steel with mechanical properties comparable to conventionally manufactured metals.
Multi-Material or Multi-Colour Parts
PolyJet
PolyJet is uniquely capable of printing with multiple materials simultaneously in a single build. This enables parts with varying rigidity, colour, and transparency -- ideal for overmould simulation and realistic prototypes.
Flexible or Rubber-Like Parts
PolyJet
Also: FDM (TPU)
PolyJet offers the widest range of Shore A hardness values (27A to 95A) using Agilus and Tango materials. For simpler flexible parts, FDM with TPU 95A filament is a more cost-effective option.
Large-Format Parts
FDM
Also: SLS
FDM supports the largest build volumes (up to 900 x 600 x 900 mm on industrial machines), making it the go-to choice for large enclosures, housings, and architectural models.
Technology Strengths and Limitations
Every 3D printing technology has trade-offs. Understanding these helps you make an informed choice for your specific application.
FDM
Fused Deposition Modeling
Strengths
Lowest cost per part among all technologies. Widest material selection including engineering-grade thermoplastics like Nylon, PETG, and carbon-fibre composites. Largest available build volumes for oversized parts.
Limitations
Visible layer lines result in rougher surface finishes compared to resin-based processes. Anisotropic strength (weaker along the Z-axis). Requires support structures for overhangs greater than 45 degrees.
SLA
Stereolithography
Strengths
Exceptional surface finish and fine feature detail with layer heights as low as 25 microns. Broad range of specialty resins including castable, biocompatible, and high-temperature formulations. Excellent dimensional accuracy.
Limitations
Parts can be brittle compared to thermoplastics and may degrade with prolonged UV exposure. Requires post-curing and support removal, adding to turnaround time. Smaller build volumes than FDM or SLS.
SLS
Selective Laser Sintering
Strengths
No support structures needed -- unfused powder supports the part during printing, enabling complex geometries and interlocking assemblies. Produces durable, functional parts with good mechanical properties in engineering-grade nylon.
Limitations
Parts have a slightly grainy, matte surface texture that may require post-processing for cosmetic applications. Limited to powder-based materials (primarily nylons). Longer cool-down cycles can extend lead times.
MJF
Multi Jet Fusion
Strengths
Faster print speeds than SLS due to the agent-based fusing process. Produces parts with highly consistent and isotropic mechanical properties. Excellent for batch production with high part density per build.
Limitations
More limited material selection compared to SLS (primarily PA12 and PA12 with glass beads). Default part colour is grey or black, limiting cosmetic options without dyeing or painting. Fine text below 0.5 mm may not resolve clearly.
DMLS
Direct Metal Laser Sintering
Strengths
Produces fully dense metal parts with mechanical properties matching wrought or cast metals. Enables complex internal channels, lattice structures, and topologically optimised geometries impossible with traditional machining.
Limitations
Highest cost among all 3D printing technologies due to expensive metal powders and slow build speeds. Requires extensive post-processing including support removal, heat treatment, and often CNC finishing. Smaller build volumes.
PolyJet
Photopolymer Jetting
Strengths
Finest layer resolution (16 microns) and smoothest surface finish of any polymer technology. Unique ability to print multiple materials with different colours and shore hardness values in a single build. Ideal for realistic prototypes.
Limitations
Parts have lower heat resistance and mechanical strength compared to thermoplastics, making them less suitable for functional testing under load. Higher cost per part. Photopolymer materials can yellow or become brittle over time.
Frequently Asked Questions
Common questions about choosing the right 3D printing technology for your project.
Which 3D printing technology is the most affordable?
FDM (Fused Deposition Modeling) is the most affordable 3D printing technology. It uses low-cost thermoplastic filaments such as PLA, ABS, and PETG, and the machines themselves are the most economical among professional-grade systems. FDM is ideal for rapid prototyping and functional testing where ultra-fine surface finish is not a primary concern.
What is the strongest 3D printing technology?
DMLS (Direct Metal Laser Sintering) produces the strongest parts since it prints in metals such as aluminium, titanium, and stainless steel. For polymer parts, MJF and SLS produce the most mechanically robust components using engineering-grade nylon (PA12, PA11), with consistent isotropic properties and high tensile strength.
Which technology gives the smoothest surface finish?
PolyJet delivers the smoothest as-printed surface finish among polymer technologies, achieving Ra values as low as 1-2 microns. SLA is a close second, producing smooth surfaces with Ra values of 2-4 microns. Both technologies are ideal for visual prototypes, master patterns, and presentation models.
Can 3D printed parts be used in production?
Yes, several 3D printing technologies produce parts suitable for end-use production. MJF and SLS are commonly used for low-to-mid volume production of functional plastic parts. DMLS produces production-grade metal components used in aerospace, automotive, and medical applications. The choice depends on volume, material requirements, and mechanical specifications.
How do I choose between SLS and MJF?
Both SLS and MJF produce strong, functional nylon parts and do not require support structures. MJF generally offers faster print speeds and more consistent mechanical properties across all axes (more isotropic). SLS provides a wider range of material options, including glass-filled and flame-retardant nylons. For high-volume production runs, MJF tends to be more cost-effective due to its faster build speeds.
What is the difference between SLA and PolyJet?
SLA uses a UV laser to cure liquid photopolymer resin one layer at a time, while PolyJet jets droplets of photopolymer resin and cures them with UV light simultaneously. PolyJet can print with multiple materials in a single build, enabling multi-colour and multi-durometer parts. SLA generally offers a wider range of engineering resins and is more cost-effective for single-material parts.
Which technology is best for metal 3D printing?
DMLS (Direct Metal Laser Sintering) is the leading technology for metal 3D printing. It uses a high-powered laser to fuse metal powder particles layer by layer, producing fully dense metal parts in materials such as Aluminium (AlSi10Mg), Titanium (Ti6Al4V), and Stainless Steel. DMLS parts achieve mechanical properties comparable to wrought or cast metals.
How long does 3D printing take?
Print time varies significantly by technology, part size, and complexity. FDM parts typically take 2-24 hours for moderate-sized parts. SLA and PolyJet can range from 1-12 hours. SLS and MJF batches typically complete in 12-24 hours but can print many parts simultaneously. DMLS metal prints often take 8-48 hours. At IamRapid, standard lead times range from 2-5 business days including post-processing.
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