Scaling Your Business with HP's 3D Printing Solutions

On 10 July 2025, HP held the third session of its Beyond the Layers of Polymers 3D Printing webinar series. Unlike the first two sessions, which highlighted customer achievements and introduced the components of the Jet Fusion system, this session centered on the path “from first success to full production.”

Justin Hopkins, HP’s application engineer manager, traced the evolution of HP's 3D printing lineup—the 5000, 5200, and 5600 series—illustrating how companies can advance from initial adoption to mass manufacturing. Rather than simply listing product features, Hopkins used a case study featuring a fictional company, Footright Orthotics, a custom insole manufacturer. This example mirrored the experience of many businesses exploring additive manufacturing, beginning with small production volumes and expanding as demand grows. “No matter your business’s stage, we’ll guide you through the journey from the 5000 to the 5600 and show you how to choose the right equipment for your needs,” Hopkins explained.

For newcomers, the Jet Fusion 5000 series represents the most affordable entry point. In the scenario, Footright Orthotics produces about 50 pairs of insoles weekly—a typical starting case—comfortably handled by the 5000 series’ 380 x 284 x 250 mm build capacity, requiring a little over one build per week. Entry-level users must consider manual powder management. The 5000 can function with or without a processing station, and cost-conscious customers may opt to manually extract, mix, and load powder despite the additional labor required. “While you save on initial investment, manual powder handling involves more effort,” Hopkins said. “Growing companies can later add a processing station to reduce manual work.”

As production scales—for instance, to 200 pairs of insoles per week—the 5000 series reaches its capacity threshold. The Jet Fusion 5200 series, with increased build height (380 mm versus the 5000’s 250 mm), enables larger batches and greater throughput. “The difference is really in build height and extra print modes,” said Hopkins. With the 5200 series, Footright Orthotics could produce 66 pairs per build, completing 200 pairs in just three builds per week instead of five. Workflow improvements at this stage, such as integrated cooling units and automated unpacking stations, further minimize labor demands and enhance efficiency, so scaling doesn’t necessarily mean more equipment or staff.

For businesses ready to fully ramp up production, the Jet Fusion 5600 series offers advanced hardware improvements to ensure greater consistency, higher reliability, and refined process control. Hopkins noted, “The 5600 features the highest uptime, lowest maintenance costs, and better thermal management, resulting in more output with fewer defects.” With the 5200, companies can expect about a 95% yield, whereas the 5600 can raise this to 97–98%.

A highlight of the 5600 series is process development software that allows precise adjustments at the job, region, or even individual part level, suitable for manufacturers with varied application needs. For instance, if Footright Orthotics began contract manufacturing for a client who prioritized speed over mechanical properties, production parameters could be tweaked accordingly. The 5600 also supports automation add-ons for automated build changeovers, reducing downtime by up to 40 minutes between jobs and making it possible to complete two full builds in 24 hours without extra shifts. Hopkins emphasized that such advances enable efficient, scalable growth.

Using this case study, HP showcased how businesses can logically scale additive manufacturing—from initial, entry-level use to high-volume automated production, with each progression tailored to business needs and minimizing unnecessary investment. Hopkins concluded, “It’s all about aligning your technology with your growth—you only want as much capacity as you’ll use.”

The upcoming webinar in the series will turn to materials, starting with PA-12 (Polyamide 12), a thermoplastic prized for its strength, durability, and chemical resistance in additive manufacturing.