FDM vs MJF 3D Printing: Advantages and Key Differences

Since the birth of 3D printing in the 1980s and through to today’s modern industrial processes, additive manufacturing has made enormous progress.
Among the most widespread and representative technologies today are:

• FDM (Fused Deposition Modelling) → the most well-known and accessible technology
• MJF (Multi Jet Fusion) → introduced by HP in 2016, now considered a game-changer for professional 3D printing

In this guide, we examine the differences, advantages, materials, applications and limitations of the two technologies, to help you choose the ideal one for your project.

• What is FDM 3D Printing
• What is MJF 3D Printing
• The FDM Extrusion Process
• How MJF Works
• FDM Materials
• MJF Materials
• Print Quality: FDM vs MJF
• Applications: When to Choose FDM and When to Prefer MJF
• Advantages and Disadvantages of FDM and MJF
• FDM vs MJF Comparison Table

WHAT IS FDM 3D PRINTING AND WHAT IS MJF?

FDM (FUSED DEPOSITION MODELLING)

This is the most widespread 3D printing technology among hobbyists, designers and small workshops.
It uses a thermoplastic filament that is melted and extruded through a nozzle, building the part layer by layer.

It is easy to use, inexpensive (consumer printers from €100–200) and ideal for quick prototypes and concept testing.

In FDM technology, a filament a) of plastic material is fed through a heated moving head b) which melts and extrudes it, depositing it, layer by layer, in the desired shape c). A mobile platform e) lowers after each layer has been deposited. For this type of 3D printing technology additional vertical support structures are required d) to support the protruding parts. Source: Wikipedia by Paolo Cignoni

MJF (MULTI JET FUSION)

This is a professional technology developed by HP and introduced in 2016.
It uses a nylon powder bed and an inkjet array that selectively deposits fusing and detailing agents, which are then melted by IR lamps.

The result?
Isotropic, strong parts, support-free, with quality comparable to injection moulding.

One of 12 HP Multi Jet Fusion printers installed by Weerg. Get an instant quote.

HOW FDM AND MJF WORK: TECHNICAL DIFFERENCES

THE FILAMENT EXTRUSION PROCESS IN FDM

• The 3D model is “sliced” using software (Cura, PrusaSlicer).

• The printer melts the filament and deposits it through a nozzle.

• Each layer solidifies before the next one is added.

• Supports are required for overhangs.

• Typical layer height: 0.1–0.5 mm.

Printing process: 1 - Print extruder, 2 - Deposited material, 3 - Construction plan.
Source: Wikipedia by Paolo Cignoni

THE POWDER-BED PROCESS IN MJF

• A roller spreads a thin layer of powder.

• Inkjet heads deposit fusing and detailing agents.

• An IR lamp selectively melts the powder.

• The surrounding powder supports the part → no supports required.

• At the end of the print, the build box is removed and the parts are cleaned.

MJF productivity is approx. 300 cm³/h, compared with approx. 10 cm³/h for FDM.

Multi Jet Fusion (MJF) process scheme: (a) stages 1-5 of the fusion process); (b) 3D construction unit; (c) processing station. Source: research gate

MATERIALS SUPPORTED BY FDM AND MJF

FDM MATERIALS

Most commonly used:

• PLA → easy, good aesthetics, biodegradable

• ABS → strong but prone to warping

• PETG → balance between strength and ease of printing

• TPU → flexible

• Nylon → strong but difficult to print

Professional FDM printers (from €25,000) can print high-performance materials:

• PEEK, Carbon PEEK, Ultem, advanced composites

FDM printing offers a good range of materials. Source filament to print

MJF MATERIALS

MJF processes high-performance industrial materials, including:

• PA12

• PA11

• PA12 GF (glass-filled)

• TPU

• PP (Polypropylene)

These materials offer mechanical properties very close to injection moulding.

PRINT QUALITY: FDM VS MJF

SURFACE FINISH

• FDM: visible layers, rough surface

• MJF: uniform, “velvety”, professional finish

DIMENSIONAL ACCURACY

• FDM: variable, depends on the printer

• MJF: very high and repeatable

MECHANICAL STRENGTH

• FDM: anisotropic → weakness along the Z-axis

• MJF: isotropic → consistent strength in all directions

DETAIL AND COMPLEXITY

• FDM: limited in fine details; requires supports

• MJF: excellent detail, no supports, ideal for complex geometries

FDM printing farm: the Prusa printing farm has over 300 FDM printers in a single room

APPLICATIONS: WHEN TO CHOOSE FDM AND WHEN TO PREFER MJF?

WHEN TO USE FDM

• rapid prototyping

• concept models

• low-cost, non-functional parts

• experimentation with special materials

Perfect for: makers, students, designers in the early stages of development.

WHEN TO USE MJF

• strong, functional prototypes

• small and medium-batch production

• technical components

• mechanical parts, snap-fits, housings

• complex geometries without supports

Perfect for: engineering, automotive, medical, robotics, advanced manufacturing.

ADVANTAGES AND DISADVANTAGES OF FDM AND MJF

FDM

Advantages

• inexpensive

• easy to use

• wide material variety

• excellent for early prototypes

Disadvantages

• low precision

• poor surface aesthetics

• limited repeatability

• common issues: warping, clogging, delamination

• supports always required

MJF

Advantages

• industrial-grade quality

• isotropic, strong parts

• no supports

• high productivity

• uniform finish

• ideal for end-use production

Disadvantages

• higher cost compared with FDM

• fewer materials

• requires industrial equipment (≈€500,000)

FDM VS MJF COMPARISON TABLE

CONCLUSIONS: WHICH SHOULD YOU CHOOSE?

The real question is not “which technology is better?” but rather:

Which technology is better for your purpose?

Choose FDM if:

• you have a limited budget

• you need fast, low-cost prototyping

• material variety is important to you

Choose MJF if:

• you need strong, functional parts

• you require industrial-grade quality

• you need small/medium-batch production

• you want complex geometries without supports

MJF is currently one of the most significant advances in industrial 3D printing, capable of competing with injection moulding in cost, speed and performance.

CREATE YOUR PROJECT WITH MJF OR FDM TECHNOLOGY