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<p>The fabrication of metallic materials into complex three-dimensional structures is essential for advancing technologies in diverse fields such as electronics, mechanical engineering, biomedical, chemical synthesis, and aerospace. Additive manufacturing (AM), a leading approach for metal part production technique, offers distinct advantages over conventional fabrication methods. In this domain, it includes direct energy deposition, powder bed fusion, and binder jetting. However, these systems are not without limitations, encompassing challenges related to process variables, material characteristics, economic feasibility, energy efficiency, and environmental considerations. Consequently, there is a pressing need to explore innovative advancements and alternative approaches in this rapidly evolving technological landscape. This detailed review explores the emerging field of metal component fabrication using fused filament fabrication (FFF) technology and mainly discusses three principal approaches to metal fabrication: fused filament fabrication of metals (FFFm), metal fused filament fabrication (MFFF), and fused filament fabrication assisted casting (FFFC). It also scrutinizes the methodologies, materials, recent innovations, benefits, and obstacles associated with each technique. FFFm concentrates primarily on alloys with low melting points, whereas MFFF employs a tripartite process of printing, debinding, and sintering metal-polymer filaments with high filler content. FFFC leverages 3D-printed molds and patterns for metal casting applications. The analysis illuminates the capacity of these techniques to surmount the limitations of conventional metal AM methods, presenting cost-effective alternatives for producing intricate metal components. Furthermore, it identifies research gaps and future trajectories, including enhancing dimensional precision, mitigating porosity, and broadening material options. This review further examines the FFF-based metal fabrication techniques holistically, offering valuable insights into their present status, challenges, and prospective applications across diverse industrial domains.</p>

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An extensive review of fused filament fabrication (FFF) methods in metal component production

  • 期刊论文

  • 发表日期：

    2025年12月22日

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  • Pretesh John,
  • Venkateswara Rao Komma,
  • Skylab Paulas Bhore,
  • Rahul Davis,
  • J. Sanjog,
  • Marcio Bacci da Silva,
  • Rosemar Batista da Silva

摘要

The fabrication of metallic materials into complex three-dimensional structures is essential for advancing technologies in diverse fields such as electronics, mechanical engineering, biomedical, chemical synthesis, and aerospace. Additive manufacturing (AM), a leading approach for metal part production technique, offers distinct advantages over conventional fabrication methods. In this domain, it includes direct energy deposition, powder bed fusion, and binder jetting. However, these systems are not without limitations, encompassing challenges related to process variables, material characteristics, economic feasibility, energy efficiency, and environmental considerations. Consequently, there is a pressing need to explore innovative advancements and alternative approaches in this rapidly evolving technological landscape. This detailed review explores the emerging field of metal component fabrication using fused filament fabrication (FFF) technology and mainly discusses three principal approaches to metal fabrication: fused filament fabrication of metals (FFFm), metal fused filament fabrication (MFFF), and fused filament fabrication assisted casting (FFFC). It also scrutinizes the methodologies, materials, recent innovations, benefits, and obstacles associated with each technique. FFFm concentrates primarily on alloys with low melting points, whereas MFFF employs a tripartite process of printing, debinding, and sintering metal-polymer filaments with high filler content. FFFC leverages 3D-printed molds and patterns for metal casting applications. The analysis illuminates the capacity of these techniques to surmount the limitations of conventional metal AM methods, presenting cost-effective alternatives for producing intricate metal components. Furthermore, it identifies research gaps and future trajectories, including enhancing dimensional precision, mitigating porosity, and broadening material options. This review further examines the FFF-based metal fabrication techniques holistically, offering valuable insights into their present status, challenges, and prospective applications across diverse industrial domains.