Turning Complexity into a Competitive Advantage (with a Little Help from MJF)

Complex Geometry: Problem or Superpower?

In today’s manufacturing world, being able to produce parts with dizzyingly intricate geometries isn’t just a bonus—it’s your superpower.

Whether you're crafting parts for rockets, reinventing medical innovation, or pushing the envelope in consumer product design, those unconventional shapes and complex structures are your edge. But let’s face it: with bold design comes serious manufacturing challenges. That is, unless you bring the right ally into the game. That’s where Multi‑Jet Fusion (MJF) steps in.

Material Considerations for Complex Geometries

The material you select fundamentally affects how successfully you can produce complex geometries:

Orientation Matters

Print orientation dramatically impacts material properties, especially fatigue resistance. Our testing on PA12 (nylon) components shows that:

• Parts printed with layers perpendicular to the primary load path can exhibit 40% less fatigue resistance than those printed with layers parallel to the load.
• This effect varies dramatically by material—some photopolymers show much less orientation dependency than thermoplastics.

Production Tips from SICAM's Experience

After producing thousands of complex parts, we've developed several practical guidelines:

Validate Before Scaling

1. Produce representative test sections: Before committing to a full complex part, print critical sections to validate both manufacturability and performance.
2. Test in real conditions: Complex geometries often behave differently under real-world conditions than in simulation. Build validation into your development timeline.
3. Iterate intelligently: Use each prototype to refine not just design but manufacturing parameters. Document what works.

Design for Assembly

Complex geometries allow for part consolidation, but smart engineers still design with assembly in mind:

1. Maintain stable base surfaces: Even the most organic-looking part needs flat, stable surfaces for fixturing and assembly.
2. Design robust connection points: Connection features should be oversized and reinforced compared to traditional designs.
3. Consider accessibility: Service access and assembly tool clearance remain crucial even with consolidated parts.

Our team recently redesigned a robotic end effector, consolidating 17 components into a single 3D-printed part while reducing weight by 43%. The key was maintaining precise mounting interfaces while optimizing everything in between.

Manufacturing Partner Communication

When working with manufacturing partners on complex geometries:

1. Share design intent, not just files: Explain which features are critical for function and which have flexibility.
2. Discuss orientation early: Align on build orientation before finalizing design details.
3. Consider DfAM reviews: Design for Additive Manufacturing reviews catch issues before they become expensive problems.

"The most successful complex geometry projects involve close collaboration between design and manufacturing teams from day one," emphasizes our Customer Service manager. "It's never too early to involve your manufacturing partner."

Imagine that far-fetched geometry you’ve been sketching—the lattices, internal channels, seamless transitions—it’s all theoretically feasible. But the real test? Turning those sketches into real parts, at scale, with precision, speed, and consistency. That’s where MJF shines brightest. Think of it as the Swiss Army knife of additive manufacturing: it jets agents across finely melted powders to deliver parts with uniform strength, immaculate surface quality, and zero need for bulky support structures. Plus, up to 80% of the unused powder can be recycled—talk about efficient. That’s real productivity and sustainability rolled into one punchy process. And with engineering-grade materials like PA11, PA12, and even elastomers, MJF isn’t just fast—it’s tough, too.

But let’s not throw shade at other technologies. Stereolithography (SLA) still reigns supreme when you need ultra-slick surfaces and microscopic detail—great for medical prototypes or form-fitting props for Sci‑Fi films. Selective Laser Sintering (SLS), meanwhile, delivers solid, functional parts. Yet, when compared to MJF, it can feel like being stuck in slow-motion—you trade more build time and less material efficiency. Fused Filament Fabrication (FFF), on the other hand, keeps costs low and works for large denser parts, but it’s not going to win any finish quality awards.

And traditional manufacturing still has muscle. Five-axis CNC machining still rules when those critical surface tolerances and finishes are non-negotiable. Injection molding, though heavy on upfront tooling, can still achieve geometries that’d make your additive machine blush—if designed cunningly.

Technology Match-Up: MJF vs. the Rest

While MJF is our go-to for complex plastic parts, it’s not the only tool in the shed. Here’s how it stacks up:

Now, design is where the fun really starts. Got conditions like minimum feature sizes? Keep them at or above 2 mm where possible. Load paths? Align them with your print orientation to dodge strength losses. Think about angles too—anything steeper than 45° means you won’t spend hours chopping away at supports. And when you’re sculpting lattices, think smarter, not lighter—sometimes, fewer beefier struts outperform a spiderweb of delicate ones.

Need heat‑managing parts? Conformal cooling channels that hug the geometry of your part can cut operating temperatures by around 23%. Trust me, designing turbulence features and varying channel diameters to control flow is worth the extra brainpower.

Then there’s the human factor. Orientation matters, especially for materials like PA12—hit a bad orientation and your fatigue resistance might drop by 40%. So, prototype smart: test your complex regions under real-world conditions, not just simulations. And during post‑processing, remember that MJF gives you a free bed of powder, but you still need smart paths for powder removal, plus finishing options like bead blasting, vapor smoothing, or hard-wearing coatings.

Complexity with Purpose

Here’s the golden rule: just because you can make it complex doesn’t mean you should.

Ask yourself:

• Does this geometry reduce weight or improve performance?

• Does it integrate multiple components into one?

• Does it make assembly simpler or heat management smarter?

If yes, go wild. If not, refine.

At SICAM, we've learned that complex parts don't win unless you design with assembly and manufacture in mind. Smooth base surfaces for fixtures, oversized connectors for easy mating, and first-hand collaboration with your manufacturing partner are game-changers. Don’t just send the STL—communicate the mission.

Because here’s the kicker: complexity for its own sake is no badge of honor. The real win comes when your complex geometry streamlines function, boosts performance, slashes assembly, or crushes weight—all while keeping manufacturability intact.

We believe complexity is only as good as the value it brings. And if you’re up for it, MJF at SICAM is here to make complexity work smarter—not just look cooler.

Lessons from the Shop Floor

After thousands of MJF builds, here’s what really works:

• Validate Before You Scale: Print a section or slice of your complex design to test fit and function.

• Design for Assembly: Keep flat faces for fixturing, oversize connectors for durability, and accessible paths for tools or fasteners.

• Communicate Early: Share your design intent and functional priorities with your manufacturer—it avoids costly assumptions down the line.