The Arburg Plastic Freeforming process (APF) is a unique additive manufacturing material jetting method. In APF, a thermoplastic material is supplied as pellets, melted and selectively deposited as droplets, enabling the use of commercial materials in their original shape instead of filaments. The medical industry could significantly benefit from the use of additive manufacturing for the onsite fabrication of customized medical aids and therapeutic devices in a fast and economical way. In the medical field, the utilized materials need to be certified for such applications and cannot be altered in any way to make them printable, because modifications annul the certification. Therefore, it is necessary to modify the processing conditions rather than the materials for successful printing. In this research, a medical-grade poly(methyl methacrylate) was analyzed. The deposition parameters were kept constant, while the drop aspect ratio, discharge rate, melt temperatures, and build chamber temperature were varied to obtain specimens with different geometrical accuracy. Once satisfactory geometrical accuracy was obtained, tensile properties of specimens printed individually or in batches of five were tested in two different orientations. It was found that parts printed individually with an XY orientation showed the highest tensile properties; however, there is still room for improvement by optimizing the processing conditions to maximize the mechanical strength of printed specimens.

Additive manufacturing (AM) nowadays has become a supportive method of traditional manufacturing. In particular, the medical and healthcare industry can profit from these developments in terms of personalized design and batches ranging from one to five specimens overall. In terms of polymers, polyolefins are always an interesting topic due to their low prices, inert chemistry, and crystalline structure resulting in preferable mechanical properties. Their semi-crystalline nature has some advantages but are challenging for AM due to their shrinkage and warping, resulting in geometrical inaccuracies or even layer detaching during the process. To tackle these issues, process parameter optimization is vital, with one important parameter to be studied more in detail, the print envelope temperature. It is well known that higher print envelope temperatures lead to better layer adhesion overall, but this investigation focuses on the mechanical properties and resulting morphology of a semi-crystalline thermoplastic polyolefin. Further, two different AM technologies, namely material jetting (ARBURG plastic freeforming—APF) and filament-based material extrusion, were studied and compared in detail. It was shown that higher print envelope temperatures lead to more isotropic behavior based on an evenly distributed morphology but results in geometrical inaccuracies since the material is kept in a molten state during printing. This phenomenon especially could be seen in the stress and strain values at break at high elongations. Furthermore, a different crystal structure can be achieved by setting a specific temperature and printing time, also resulting in peak values of certain mechanical properties. In comparison, better results could be archived by the APF technology in terms of mechanical properties and homogeneous morphology. Nevertheless, real isotropic part behavior could not be managed which was shown by the specimen printed vertically. Hence, a sweet spot between geometrical and mechanical properties still has to be found.