A novel solid ink system enables significant enhancements to jetting frequency, automatic document feed (ADF) performance, and enhanced “feel” while maintaining the excellent durability of legacy solid ink technologies. Development of this solid ink system required the balance of numerous performance properties against a host of system requirements. Design of Experiment (DOE) methodologies were used extensively to define the interrelationships between materials and their contributions to the various performance factors. Mechanical properties of the inks were defined by dynamic mechanical analysis (DMA). These mechanical properties were characterized as a function of component proportions and the ink components were classified according to their mechanical contributions to the system. Critical performance factors such as durability and ADF were linked to these properties throughout the developmental process. Finally, tradeoffs of performance features were defined and tolerances for component variation were established to ensure robust design performance.