Efficient Powder Removal & Post-Processing Tips for MJF Parts
Why this matters
Designing for Multi Jet Fusion (MJF) is only half the story. What happens after printing—during powder removal and post-processing—can significantly impact part quality, lead times, and usability. Here’s how engineers and buyers can avoid common pitfalls and optimise for real-world production.
Design for Easy Powder Escape
Add drain holes: For hollow parts or internal channels, include at least two powder escape holes, ideally opposite each other. Holes ≥ 5 mm are effective for most parts.
Use strategic geometry: In long channels or cavities, internal ribs or flow guides help loosen and evacuate trapped powder during cleaning.
Open Up Internal Structures
Lattice designs: Use internal lattices with at least 1 mm spacing between elements to allow powder to flow out easily.
Large cavities: Don’t leave hollow spaces sealed—without escape paths, powder builds up and increases weight, shipping cost, and post-processing time.
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Plan for Cleaning Media Access
Minimum access size: Internal features should have openings of at least 6.5 mm to allow tumbling or blasting media to reach and clean them.
Avoid fragile features: Fine pins or thin walls may break during automated cleaning steps. Make sure fragile details are shielded or reinforced if post-processing is required.
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Know the Surface Differences
Internal vs. external quality: Internal surfaces typically receive less cleaning and smoothing than external ones. Avoid relying on critical dimensions or sealing surfaces inside closed features.
Minimum wall thickness: Stick to ≥ 1 mm walls for parts that will go through vibratory or bead blasting. Thinner walls may deform or break under stress.
Start Your Manufacturing Project with MakerVerse
MakerVerse is a platform for sourcing industrial parts. It provides instant access to a vetted supply chain and a full range of manufacturing technologies. With AI-powered quoting, order management, and fulfilment, MakerVerse helps with everything from initial prototypes to full-scale production.
Scale Smart with Post-Processing Automation
Tumbling & blasting: For series production, automated post-processing (e.g., tumble cleaning, vapour smoothing) can drastically cut labour time and boost consistency.
Parameter optimisation: Automation tools can adjust cleaning time and intensity based on part geometry, reducing cycle time while maintaining finish quality.
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Benefits of Optimising Powder Removal Early
| Design Action | Production Benefit |
|---|---|
| Add accessible drain paths | Faster powder removal, lower weight |
| Avoid closed-off cavities | Easier post-processing, fewer rejects |
| Use robust wall thicknesses | Reduced risk of damage in finishing |
| Enable access for cleaning media | Consistent surface quality |
Pro Tip for MakerVerse Users
Upload your part as usual; our quoting system handles design checks automatically. But if your part includes enclosed features or tight lattices, consider adding drain holes or access points. You’ll speed up delivery and improve the quality of the final part.
