HP Jet Fusion 540

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Printer from the front

The HP Jet Fusion is unique here due to the usage of Jet Fusion technology rather than FDM. Jet Fusion is an additive technique that uses a heating lamp to harden a powdered material. This gives the advantage that support material is not needed as each layer is already supported by the unhardened powder.

The Jet Fusion is great for creating large batches of the same model, printing complex geometry, and for creating robust parts. Keep in mind that post-processing of the parts is necessary, which potentially can be quite time-consuming.

Preparing your model

This printer should only be running after work hours due to high noise

  1. Open your 3D model with HP SmartStream 3D Build Manager
  2. Create duplicates or add other desired parts
  3. Use auto-pack to spread the parts
  4. Make adjustments if necessary
  5. Press "Send to print" to submit your job to the printer
  6. Choose your print job at the printer
  7. Turn on the shop vac by the window

Tip on printing layout

Keep in mind that heat from sintered material rises, and to prevent warping or inconsistent prints make sure that heat is able to escape freely and not get trapped inside your model. In many cases, orienting the print so that the most material is sintered at the top can be a good idea.


Wearing a dust mask, gloves, and a lab coat is highly recommended during all steps of post-processing due to dust from unsintered material.

  1. Select material recovery on the display to add unused material back into the printer
  2. Remove your part(s)
  3. Follow the on-screen guide for vacuuming and cleaning the printer
  4. Head on over to the sandblaster to remove unsintered powder from the print
  5. Use the ESD-armband when sandblasting as it creates high amounts of static electricity that will shock you otherwise

Link to HP Product page: [1]

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