Materials Today: Proceedings 52 (2022) 1309–1313

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Materials Today: Proceedings

journal homepage: www.elsevier.com/locate/matpr

A comprehensive review of emerging additive manufacturing (3D

printing technology): Methods, materials, applications, challenges,
trends and future potential
Praveena B.A a,⇑, Lokesh N a, Abdulrajak Buradi a, Santhosh N b, Praveena B L a, Vignesh R a
a
Department of Mechanical Engineering, Nitte Meenakshi Institute of Technology, Bengalure 560064, Karnataka, India
b
Department of Mechanical Engineering, MVJ College of Engineering, Bengalure 560067, Karnataka, India

a r t i c l e i n f o a b s t r a c t

Article history: Additive manufacturing is a fabrication technique that is transforming the industrial and manufacture
Available online 18 November 2021 industries. Due to its numerous advantages, additive manufacturing has become a popular trend in man-
ufacturing processes. It is defined as the method of fabricating parts via layer-by-layer deposition of
Keywords: quantifiable. The main benefits of 3D printing or additive manufacturing (AM) are design liberty, bulk
3D Printing customization, unwanted minimization, and the capacity to build complicated assemblies, as well as
Hybrid manufacturing rapid prototyping. A comprehensive review of emerging additive manufacturing technology in 3D print-
Subtractive manufacturing
ing, materials, methods, applications, challenges and future potential their evolution in popular applica-
Additive manufacturing
Composites
tions was carried out. Overall, this study provides an summary of 3D printing, as well as a study of its
Biomaterials advantages and disadvantages, to serve as a baseline for prospect investigation and improvement. This
review will assist readers in comprehending the various features of additive manufacturing and identi-
fying new areas for upcoming investigation.
Copyright Ó 2022 Elsevier Ltd. All rights reserved.
Selection and peer-review under responsibility of the scientific committee of the International Confer-
ence on Smart and Sustainable Developments in Materials, Manufacturing and Energy Engineering

1. Introduction this skill becoming further reachable is the expiration of prior

3D printing is an additive manufacturing method for creating an
inclusive variety of assemblies and intricate shapes from three
dimensional model data. The procedure entails printing consecu-
tive deposits of materials on top of one other. Stereolithography
(SLA), which was quickly followed by breakthroughs such as con-
tour crafting, inkjet printing, fused deposition modelling, powder
bed fusion [1,2]. 3D printing, which employs a wide range of tech-
niques, materials, and apparatus, has progressed through period
and has the possible to alter industrial and logistics. Prototyping,
building and biomechanical engineering are just a few of the busi-
nesses that use additive manufacturing. In spite of the aids of 3D
printing, such as adoption, automation and reduced waste has
been slow and limited in the construction industry [3,4].
New uses emerge as new materials and technology for additive
manufacturing are established. Some of the foremost reasons for
⇑ Corresponding author.
E-mail address: praveena404@gmail.com (P. B.A).
copyrights, which has allowed fabricators the selection to enter-
prise innovative 3D printing equipment [5]. 3D printers have
become more affordable as a result of recent improvements, per-
mitting them to be employed in extra spaces such as laboratories,
libraries, houses and schools. 3D printing was first widely recycled
by designers and engineers to construct beautiful and useful sam-
ples outstanding to its quick and profitable prototyping capacity
[6].
The use of 3D printing technology has decreased the extra
expenditures involved with product development. 3D printing,
on the other hand, has just lately become popular in a number of
productions, subsequently patterns to final end products. Product
selection has been a contest for industrialists due to the great
expenses of manufacturing tradition things for end users. Additives
manufacturing, on the further influence, has the ability to 3D print
minor numbers of customised objects at a reasonable cost [7]. This
is particularly important in the biomedical area, where one-of-a-
kind patient-specific goods are frequently required. According to
some researchers, custom functional goods are attractive the trend

https://doi.org/10.1016/j.matpr.2021.11.059
2214-7853/Copyright Ó 2022 Elsevier Ltd. All rights reserved.
Selection and peer-review under responsibility of the scientific committee of the International Conference on Smart and Sustainable Developments in Materials,
Manufacturing and Energy Engineering
P. B.A, L. N, A. Buradi et al.
in 3D printing, with around 60% of 3D printing devoted to commer-
cial product manufacture by 2020. The ability of this technique to
generate a extensive diversity of medicinal transplants using com-
puted tomography imaged tissue models has piqued the interest of
individuals in the medical industry. 3D printing has newly
expanded popularity in the building business [8].
Molds have a number of drawbacks, including their recyclabil-
ity and framework size constraints for a variety of essential
machineries. Several freeform machineries are cast in-situ, where
excellence control is difficult to achieve [9]. As a result, extraordi-
nary presentation works (such as columns and beams) are manu-
factured in carefully measured settings. In Additive
Manufacturing (AM) procedures, several 3D techniques are used,
such as 3D scanning in the numerical manufacturing procedure
and for file generation [10].
There are several challenges and limitations with 3D printing,
such as the printed building materials’ poor rigidity and strength,
as well as the printing dimension. Through their 3D printer and
an mechanized robotic arm, claimed that the WinSun company
could produce a huge construction component. Researchers used
a D-shape printer to produce physical apparatuses with cross-
sections up to 70 m by pouring liquefied on powder-based ingredi-
ents [11]. Additional drawback is that the proposed printed magni-
tude does not match the standards of entirely 3D printers, as
separately printer has its unique set of structural element fabrica-
tion specifications. Concerns have also been raised with 3D print-
ing technologies, such as the requirement for support to support
the load of the produced thing till the substantial becomes suffi-
ciently strong. Another problem for 3D printing concrete is mix
design and the use of coarse particles. In their 3D printing applica-
tion [12].
Production of layer by layer three dimensional assemblies
straight from computer aided design (CAD) drawings is the origin
of 3D printing machinery [13]. 3D printing is a cutting-edge tech-
nology that has established to be extremely adaptable. It opens up
different choices and stretches initiatives hopeful to growth their
industrial productivity. The materials that can presently be manu-
factured utilising 3D printing technology include traditional ther-
moplastics, metals, grapheme based materials and ceramics.
Table 1 shows the Summary of the methods, application, benefits
and resolution range of additive manufacturing.
3D printing technology has the probable to revolutionise indus-
try and production processes. Fabrication will be low while costs
are reduced thanks to 3D printing technology. Customer request
will have a stronger impact on production at the same time [14].
Consumers have more control over the finished product and can
request that it be manufactured to their precise conditions. Mean-
while, 3D printing facilities will be placed nearer to customers, per-
mitting for a further flexible and approachable industrial method
as well as improved superiority control [15]. Additionally, 3D
printing equipment minimises the need for international transit.
This is due to the fact that when manufacturing locations are
nearer to the ultimate target, all supply may be done utilising fleet
Table 1
Summary of the methods, application, benefits and resolution range of additive
manufacturing.
Methods Applications Benefits
Stereolithography casting, tooling and cost-effectiveness,
production line flexibility, and
design precision
Fused deposition automotive, Wide variety of
modelling aerospace, thermoplastics
Laminated object Foundry industries Sanding, drilling
manufacturing
Materials Today: Proceedings 52 (2022) 1309–1313
tracking technology, saving time and energy. Finally, the accep-
tance of 3D printing machinery may have an impact on the com-
pany’s logistics. Logistics departments inside companies can
manage the whole route and offer additional inclusive, end-to-
end facilities [16].
1.1. Manufacturing processes
Advanced and innovative investigation initiatives linked with
industrialized procedures, resources, and product plan are critical
to industry evolution. In addition to the traditional expectations
for cheap prices and high quality in today’s manufacturing produc-
tions is linked to demands for things that are more intricate, have
smaller lifespan, quicker distribution periods, require less cus-
tomization, and need less qualified personnel. In truth, today’s
products are extremely difficult to develop. As a result, there is a
tremendous incentive to create, test, and apply new and innovative
production techniques [17].
Compared to traditional manufacturing methods, Additive
manufacturing has further controlled process constraints and a
stronger lively communication among material qualities and
method factors. Material preparation, layer formation technique,
stage variation occurrence, material type, and application require-
ments all influence the type of AM process used. The testing phase,
design phase, and processing phase are the three primary phases of
the AM process [18].
2. Additive manufacturing methods
The Additive manufacturing technique uses digital data from
the computer to manufacture parts layer by layer from the lower-
most up. Additive manufacturing is made up of a number of sepa-
rate processes, each with its own set of benefits and drawbacks
[19].
2.1. Powder bed fusion process
To fuse and melt microscopic particles of powder to construct
3D objects. Polymers, metals, ceramics, and composites are among
the materials used in this technique. SLS, EBM, SLM, SHS, and DMLS
are some of the techniques employed in this process [20].
2.2. Photopolymerization process
Photo-polymerization is an AM technology that customs a liq-
uid polymer resin to create 3D objects. This method involves cur-
ing a photopolymer resin using a UV laser to create prototypes,
models, and patterns. The materials utilized in this procedure are
various polymer grades. In this procedure, Stereolithography
(SLA) is the most often utilized technology. Some of the assemblies
in this method may require a provision system to prevent the item
from deforming. These supports are made of the same material as
the rest of the item and can be cut away using sharp tools. The fin-
ished part is cured in a UV oven after being rinsed in a chemical
bath to remove excess resin [21].
Resolution
2.3. Extrusion-Based systems
range (lm)
7 lm (3) Plastic prototypes and low-volume functional parts are pro-
duced using extrusion-based techniques. Fused Deposition Model-
30– ing is the most widely utilized extrusion-based technology (FDM),
120 lm (4) an extrusion-based method for prototyping, modelling and fabrica-
85 lm (5) tion claims. A modelling substantial for the completed item and a
provision material used in this method [22].
1310
P. B.A, L. N, A. Buradi et al.
3. Materials used for additive manufacturing 3D printing
technology
To produce reliable good products, 3D printing, like some other
engineering method, needs good quality materials that fulfil strict
criteria. End-users, purchasers and suppliers of the material
develop methods, requirements, and material control agreements
to ensure this. Ceramic, polymers and metals their mixes in the
method of composites, hybrid or functionally graded materials
are all capable of producing completely functional parts using 3D
printing technology [23].
3.1. Metals and alloys
Metal 3D printing technique has piqued attention in the auto-
motive, aircraft, manufacturing and medical industries due to the
advantages it offers. Metals have excellent physical properties
and can be used in a inclusive variety of applications, plus human
organ printing and aircraft parts. Only a few examples of these
materials include titanium alloys, nickel-based alloys, cobalt-
based alloys and aluminium alloys. In 3D printed dental applica-
tions, cobalt-based alloys are appropriate [24].
3D printing is often used to create polymer components, reach-
ing from patterns to functioning assemblies with complex geome-
try. By fused deposition modelling, it can make a 3D printed object
by depositing successive layers of extruded thermoplastic fila-
ments like fused deposition modelling, polyethylene, polypropy-
lene, acrylonitrile butadiene styrene (ABS), and polylactic acid
(PLA). PEEK and PMMA thermoplastic filaments with higher melt-
ing temperatures have recently been employed as 3D printing
materials [25].
3.2. Smart materials and composites
Smart materials are ones that can modify an object’s geometry
and shape in reaction to environmental influences such as water
and heat. Two examples of 3D printed products made with smart
constituents are a self-evolving assembly and a soft robotics struc-
ture. The terms 4D printing materials and smart materials are
interchangeable. Group smart materials include, for example,
shape memory metals and shape memory polymers. Biomedical
implants and tiny electromechanical devices use shape memory
alloys like nickel-titanium [26].
Composite materials with outstanding low weight, and adapt-
ability features have revolutionized extraordinary routine sectors
[27,28,29]. Composite materials include glass and carbon fiber
reinforced polymer composites and, to name a few [30,31]. Carbon
fibre reinforced polymer composite assemblies are extensively
employed in the aerospace engineering due to fatigue perfor-
mance, corrosion resistance, strength and high specific stiffness
[32].
4. The applications of additive manufacturing
4.1. Aerospace industry and automotive industry
In component and manufacturing design, 3D printing technol-
ogy allows unrivalled freedom. 3D printing technology in the aero-
space sector proposals the capability to produce lightweight parts
with well and complex contours, dropping energy and source
necessities. At the similar period, by decreasing the volume of
material used to fabrication of aeronautical parts, 3D printing tech-
nology can help save money on fuel [33].
3D printing technology has revolutionized the way we develop,
design and manufacture innovative products in our sector today. In
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Materials Today: Proceedings 52 (2022) 1309–1313
the locomotive production, 3D printing has created a phenomenon
by permitting for lighter and further complicated configurations to
be created in a shorter amount of time. In 2014, Local Motor, for
example, created the world’s first 3D printed electric vehicle. Local
Motors not only manufactures vehicles, but also a 3D-printed bus
known as OLLI, extending the breadth of applications of 3D print-
ing expertise [34].
5. Trends in additives manufacturing
STL process that uses a laser to harden little layers of ultraviolet
light sensitive liquid polymer. With fewer experienced personnel,
faster delivery times, and smaller product life cycles, it can suc-
cessfully create complicated and customized items. The additive
manufacturing principle was created, or an existing one was
improved upon. It can be stated that in the future, Industry 4.0,
AM will undoubtedly transform and revolutionize production
[35]. The demand for AM has expanded beyond automobiles and
aero planes to include house construction, as well as the food,
medical and space productions. The NASA has been working with
Zero-G technologies to produce effective and efficient 3DP. The
investigators have been working on producing micron-sized 3D
printed particles that can be used in the manufacture of tiny
devices and batteries [36].
6. Challenges in additives manufacturing
There are various advantages to AM, including design flexibility,
the capacity to print complicated assemblies, simplicity of use, and
product personalization. Still additive manufacturing technology
has not yet reached a point where it can be used in actual uses.
As well as technological advancement, there have been drawbacks
and impediments that must be investigated [37]. Part size limita-
tions, elephant foot, over-extrusion, layer misalignment, gaps in
the top layers, under-extrusion, pillowing, warping, poor accuracy,
low manufacturing efficiency, high costs, the construction of over-
hang surfaces, anisotropic mechanical properties and material lim-
itations are just a few of the challenges that need to be addressed
further [38].
6.1. Void formation and small build volume
One of the biggest problems of AM components is the creation
of voids between successive layers. This type of issue arises as a
result of poor layer bonding, resulting in poor mechanical perfor-
mance. Extrusion based additive manufacturing tools like fused
deposition modelling, for example, cause voids to grow between
the manufactured layers, resulting in anisotropic mechanical char-
acteristics and delamination [39]. The quantity of permeability
caused by void creation is, in fact, typically dependent on the type
of additive manufacturing method employed and the material used
[40]. The user of AM technology must also contend with a limited
build volume. It is regarded as some of the most significant draw-
backs of additive manufacturing skill. Huge portions are typically
scaled down or divided into subparts, which takings time and
energy. Furthermore, in most circumstances, scaling down the
model is not practical or effective. When adhesives are used, the
assembly of subparts loses strength, and when mechanical fasten-
ers are utilised, the assembly becomes bulky. AM has yet to prove
successful in large-scale industrial applications [41].
7. Future potential of additives manufacturing
AM will propel Industry 4.0 forward in determining the global
industrial market’s destiny in the coming decades. Industry 4.0 is
P. B.A, L. N, A. Buradi et al.
a self-optimizing, adaptable, and cognitive factory. All industry
sectors will be transformed if AM is combined with cloud comput-
ing, robotics, IoT and big data. 3D printing is broadly observed as a
watershed moment in industrial manufacturing field [42]. Profes-
sional 3D printers will continue to boost innovation and encourage
enterprises in a diversity of productions, comprising electronics,
healthcare, manufacturing, aerospace, automobiles, construction,
fashion, jewellery, entertainment, and food [43–50].
8. Conclusion
This evaluation covers a inclusive range of 3D printing applica-
tions in the industrial business. 3D printing expertise is currently
creation its way into the production engineering, and it offers
numerous benefits to individuals, corporations, and governments.
As a outcome, additional data is required to create strategies for
improving 3D printing technology use. Companies and govern-
ments can benefit from further evidence around 3D printing tech-
nology as they upgrade and improve their 3D printing
arrangement. As a outcome, the goal of this article is to offer an
indication of the many types of 3D printing technologies, con-
stituents used in 3D printing technology in the manufacturing
field, and 3D printing technology applications. Researchers will
be able to explore the numerous types of 3D printing machines
as well as the proper resources for each machine in the future.
Innovative investigation in manufacturing materials, methods
and product design is necessary for advancements in the manufac-
turing business. New and creative production procedures are
required as product difficulty grows. Because of the various bene-
fits it suggestions as well as the problems it must face, additive
manufacturing has become a current trend in manufacturing pro-
cesses. The research community has conducted a thorough analysis
and review. An in-depth examination of AM has been conducted in
this paper. The significance of part alignment, estimation of build
time, and budget computation has been thoroughly examined.
The identification of difficulties connected with various AM
approaches is the most essential aspect of this research. Part size
restrictions, anisotropic mechanical qualities, high prices, poor
precision, mass production, wrapping, layer misalignment and
material limitations are only a few of the key AM issues that
require more research and development.
CRediT authorship contribution statement
Paveena B A: Abstract, Introduction. Lokesh N: Data Curation.
Abdulajak Buadi: Investigation. Santhosh N: Methodology.
Paveena B L: Conceptualization. Vignesh R: Conclusion.
Declaration of Competing Interest
The authors declare that they have no known competing finan-
cial interests or personal relationships that could have appeared
to influence the work reported in this paper.
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