PolyJet used to mean choosing looks over strength. Smooth surfaces, crazy detail, but fragile parts. With ToughONE, that tradeoff is gone.
What Is Stratasys ToughONE?
ToughONE is a PolyJet material designed for functional parts that combine high toughness, impact resistance, and full-color printing. It bridges the gap between aesthetic prototypes and production-ready performance.
At CADimensions, we work with engineers across the additive manufacturing world who are constantly balancing design freedom with functional performance. Historically, PolyJet technology has been unmatched for aesthetics, with full-color parts, ultra-smooth surface finishes, and fine feature resolution. But when it came to mechanical strength, PolyJet materials often took a back seat to technologies like Fused Deposition Modeling (FDM) or Powder Bed Fusion (PBF).
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Why ToughONE Changes the Game for PolyJet Users
That changes with the arrival of ToughONE, a new PolyJet material from Stratasys designed to bridge the gap between visual prototyping and functional end-use parts.
ToughONE is engineered to provide superior toughness, impact resistance, and functional durability while maintaining the featured PolyJet advantages of high-resolution, full-color prints. This opens new doors for engineers and designers looking to create realistic, functional prototypes without sacrificing design complexity or surface quality.
At CADimensions, we’ve seen how ToughONE changes the game. It offers improved mechanical properties, including higher elongation at break and greater impact resistance. That makes it ideal for snap-fit assemblies, living hinges, and jigs or fixtures that face moderate mechanical stress. Whether you’re testing a consumer product enclosure or working through design iterations that require mechanical validation, CADimensions can help you put ToughONE to work for real-world performance.
When fully cured, ToughONE mimics the behavior of commonly used thermoplastics such as ABS, Polycarbonate, or Polypropylene. Additionally, fully cured ToughONE is immediately ready for a wide range of post processes such as drilling, tapping, or machining.
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How Does ToughONE Compare to Other 3D Printing Materials?
Stratasys testing aligns with what CADimensions customers experience in the field. In the published eBook “5 Ways Tough PolyJet Materials Will Transform Your Prototyping”, ToughONE is shown to deliver tensile strength of 48 to 53 MPa, impact resistance of 170 to 250 J/m, and heat resistance up to 62 °C in its base form. Reinforcing ToughONE with digital materials pushes those numbers higher, giving engineers even more flexibility when balancing strength, toughness, and thermal performance. The same report highlights applications like thin-walled casings, self-tapping screw assemblies, and snap-fit electronics, proving that ToughONE can handle detailed prototypes while still standing up to functional testing. These results explain why CADimensions recommends ToughONE for teams who want PolyJet prototypes that look like final parts and perform like them too.
| Material | Strength | Finish | Color Options | Best Use |
|---|---|---|---|---|
| ToughONE | High toughness + impact resistance | Smooth | Full color | Functional PolyJet prototypes |
| ABS (FDM) | Strong | Layered | Limited | Durable prototypes, tooling |
| Nylon (PBF) | Very strong | Rougher | Limited | End-use parts, high stress |
A number of PolyJet users have already adopted ToughONE for a variety of applications including:
- Functional Prototypes such as enclosures and housings
- Assembly Validation for snap-fit parts and moving joints
- Robotics Components that require high strength-to-weight ratios
ToughONE is a game-changer for PolyJet users who want more than just form — they want function. It expands what’s possible with rapid prototyping, allowing teams to iterate faster and get closer to production-ready performance earlier in the design cycle.
If you're looking to move from “just visual” to “truly functional” with PolyJet, ToughONE might just be the material you've been waiting for.
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Breaking It Down: Simple Answers To ToughONE Questions
Is ToughONE stronger than ABS?
When fully cured, ToughONE mimics the performance of ABS, Polycarbonate, and Polypropylene, while offering PolyJet’s smooth finish.
Can I machine or tap ToughONE parts?
Yes. Fully cured ToughONE can be drilled, tapped, or machined.
Is ToughONE ready for end-use parts?
Yes. It’s validated for functional prototypes, jigs, and fixtures that require real-world durability.
Should You Use ToughONE for Your Next Project?
If you’ve been stuck choosing between beautiful but fragile PolyJet parts and durable but rougher prints, ToughONE changes the equation. It gives you both form and function, helping you iterate faster and get closer to production-ready results earlier in the design cycle.
Have a part in mind?
Check out our instant quoting tool below and start printing with ToughONE today!
