Functional Materials for Additive Manufacturing: Materials Design, Processing, and Emerging Applications

Area of Science:

• Materials Science
• Manufacturing Engineering
• Polymer Science

Background:

• Additive Manufacturing (AM) has advanced from rapid prototyping to fabricating complex functional components.
• Polymers are dominant in AM due to processability, but AM now includes composites, nanocomposites, and metals.
• Understanding material design, processing, microstructure, and properties is crucial for AM advancements.

Purpose of the Study:

• To review functional materials for additive manufacturing.
• To emphasize the links between material design, processing, microstructure, and properties.
• To discuss current challenges and future trends in AM materials.

Main Methods:

• Review of functional polymer systems (conductive, stimuli-responsive, elastomeric, high-performance, bio-based, nanocomposites).
• Examination of processing-structure-property relationships in polymer and metal AM.
• Discussion of anisotropy, defects, residual stresses, and post-processing effects.

Main Results:

• Functional polymers and advanced materials are key for AM.
• Processing conditions significantly influence microstructure and final component properties.
• Anisotropy, defects, and residual stresses are critical factors in AM performance.

Conclusions:

• Advances in materials science are expanding AM capabilities for engineering and biomedical applications.
• Intelligent manufacturing approaches like multi-material and 4D printing are emerging trends.
• Machine learning and digital design will optimize AM material development.