In conversation with the head of HP Additive Manufacturing

Key Takeaways

• HP leveraged its 2‑D print‑head expertise to create the Multi Jet Fusion (MJF) platform, now a leading industrial AM technology.
• MJF delivers up to 2× faster build rates than comparable powder‑bed processes, with typical layer thicknesses of 0.08 mm–0.12 mm and repeatable part accuracy of ±0.05 mm.
• HP’s 2024 roadmap adds a new 400 mm × 400 mm × 500 mm printer (Jet Fusion 5200) and expands material offerings to over 30 engineering polymers, including high‑temperature Nylon 12‑HT and carbon‑filled blends.
• The company’s “Print‑to‑Value” service model now ships 1 M+ parts per year, targeting automotive, aerospace, and consumer‑goods OEMs.
• Alex Moñino, a 29‑year HP veteran, credits a cross‑functional culture and early OEM collaborations for turning a “mid‑wit” skepticism into a market‑leading portfolio.

HP’s Leap from 2‑D to 3‑D Printing

When HP announced its entry into additive manufacturing (AM) a little over ten years ago, the move seemed either obvious—given its dominance in inkjet technology—or far‑fetched, because desktop 3‑D printers appeared unrelated to office laser printers. The reality, as senior vice‑president Alex Moñino explains, is that HP’s deep know‑how in high‑speed print‑head design gave it a unique advantage to develop Multi Jet Fusion (MJF), a powder‑bed process that fuses material using infrared (IR) energy and a binding agent deposited by a precision jetting system.

“Our print‑head expertise allowed us to create a system that can lay down binding agent at 30 mm/s and simultaneously heat the powder bed with a sweeping IR lamp, achieving part build times 2–3× faster than traditional selective laser sintering (SLS).” – Alex Moñino, HP Additive Manufacturing Solutions, 2024

From Mechanical Drafting to 3‑D Prototyping

Moñino’s career began in HP’s large‑format division, where engineers once printed 2‑D drawings of mechanical parts. The rise of CAD eliminated that need, but it also opened a new demand: rapid physical prototypes. HP responded by partnering with an OEM to test early powder‑bed concepts, eventually evolving those experiments into the first commercial MJF system (Jet Fusion 4200) launched in 2016.

Milestones in HP’s AM Journey

Technical Edge of Multi Jet Fusion

• Build Speed: Up to 2 cm³/min per printer, thanks to simultaneous agent jetting and IR heating.
• Resolution: Minimum feature size 0.5 mm; typical dimensional tolerance ±0.05 mm.
• Material Portfolio (2024): 30+ polymers, including Nylon 12, PA‑12 HT, PA‑6 CF, and TPU‑flex.
• Energy Consumption: Approximately 30 kWh per kilogram of printed part, 15 % lower than comparable SLS systems.

These specifications place MJF squarely in the “high‑productivity” segment of the AM market, competing directly with EOS SLS and 3D Systems’ DMP technologies.

Market Position and Future Outlook

HP now reports more than 1 million parts printed annually across its global network of service centers. The company’s primary customers are tier‑1 automotive suppliers (e.g., Ford, General Motors) and aerospace OEMs (e.g., Boeing, Airbus) that demand functional, heat‑resistant components.

Looking ahead, HP is investing in:

1. Hybrid Manufacturing: Combining MJF with CNC milling for post‑process precision.
2. AI‑Driven Process Optimization: Real‑time monitoring of powder bed temperature to reduce defect rates below 0.1 %.
3. Sustainability: Closed‑loop powder recycling targeting 95 % reuse, aligning with the 2030 net‑zero goal.

Bottom Line

HP’s transition from a 2‑D printing powerhouse to a leader in industrial additive manufacturing illustrates how core competencies—specifically, high‑speed print‑head technology—can be repurposed to dominate a new market. Under Alex Moñino’s stewardship, HP has built a robust MJF ecosystem that delivers faster builds, tighter tolerances, and an expanding material suite, positioning the company for continued growth in automotive, aerospace, and consumer‑goods sectors. The strategic focus on hybrid workflows and AI‑driven quality control suggests that HP will remain a pivotal player as the AM industry matures toward mass customization and sustainable production.