MJF can produce higher-resolution parts of the two, and its raw material is significantly more isotropic and recyclable. SLS machines are available with larger build volumes, though.
SLS vs. MJF: Technology Comparison
SLS and MJF are both powder-bed fusion technologies. Powder bed fusion (PBF) means that parts are cumulatively built up one layer at a time by fusing powdered thermoplastics. SLS uses a CO2 laser to fuse the particles. Meanwhile, the MJF process depends on an infrared heat source, preheated powder, and a specialized fusing agent that all work together to fuse the particles.
SLS vs. MJF: Material Comparison
SLS and MJF extensively use polyamides like nylon 12 and 11, TPU (thermoplastic polyurethane), TPA (thermoplastic polyamide), and polypropylene. SLS is also able to print with carbon- and aluminum-filled nylon. Specialized high-temperature SLS machines manufactured by EOS can print in engineering thermoplastics like PEEK (polyether ether ketone). Overall, SLS works with a broader range of materials.
SLS vs. MJF: Product Applications Comparison
SLS and MJF are used to create functional parts such as casting patterns, medical devices, and elastomeric parts. The parts made using MJF are typically stronger because they are almost entirely isotropic. Regarding aesthetics, MJF products have a dull, uneven gray color and can only accept black dye. However, SLS parts can be built or dyed with many colors, making them ideal for visual prototypes. Overall, MJF offers slightly better mechanical properties than SLS.
SLS vs. MJF: Print Volume Comparison
SLS machines have larger build volumes when compared to MJF. SLS can print more nested parts in a single run with a larger build area. Large 3D-printed parts can often warp, but it’s more of a problem for MJF processes than SLS. With SLS printing, it is important to utilize as much of the build volume as possible because so little of the powder can be recycled.
SLS vs. MJF: Surface Finish Comparison
SLS and MJF parts both have a characteristic rough/matte surface finish. However, in both cases, technicians can smooth the surfaces via bead blasting, air blasting, tumbling, or water blasting. Chemical vapor smoothing has recently allowed both SLS and MJF parts to achieve a sealed, semi-gloss surface at low costs.
SLS vs. MJF: Cost Comparison
SLS and MJF have similar print costs when scaled up. However, MJF becomes cheaper when scaled up compared to SLS. MJF is more competitive because the printing process is slightly faster and the unused material more recyclable. The table below shows the price comparison for SLS vs. MJF:
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