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<p>SS316L is among the most widely adopted alloys in additive manufacturing due to its corrosion resistance, weldability, and balanced mechanical performance. While laser powder bed fusion (LPBF) enables near fully dense SS316L components, its high capital cost, energy demand, and operational complexity limit accessibility. Material extrusion of metal–polymer filaments—implemented as fused filament fabrication (FFF) or bound metal deposition (BMD)—has therefore emerged as a cost-effective alternative, producing parts through an extrusion–debinding–sintering (FDMS) process chain. This review critically examines the process physics and manufacturing science of SS316L metal FFF, emphasizing interdependencies between powder morphology, binder chemistry, filament rheology, bead deposition, debinding transport, and sintering densification. Attention is given to defect initiation and evolution, showing how printing-induced interlayer voids and debinding-derived pore networks govern final pore architecture, anisotropy, dimensional accuracy, and mechanical reliability. Typical mechanical property ranges and microstructural characteristics are synthesized in relation to process conditions and post-densification strategies such as hot isostatic pressing. The review further evaluates modeling approaches for extrusion and sintering and highlights the need for standardized reporting. Overall, SS316L metal FFF occupies a scalable niche between prototyping and functional production, with future progress driven by advanced feedstocks, defect-aware simulation, and performance-based design guidelines.</p>

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Extrusion-based additive manufacturing of SS 316 L: current capabilities, process–structure–property relationships and defect control

  • 期刊论文

  • 发表日期：

    2026年6月2日

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  • Taimoor Abbasi,
  • Maqsoora Nazim,
  • Haris Ali Khan,
  • Kamran Khan,
  • Hafiz Qasim Ali,
  • Muhammad Nafees Mumtaz Qadri

摘要

SS316L is among the most widely adopted alloys in additive manufacturing due to its corrosion resistance, weldability, and balanced mechanical performance. While laser powder bed fusion (LPBF) enables near fully dense SS316L components, its high capital cost, energy demand, and operational complexity limit accessibility. Material extrusion of metal–polymer filaments—implemented as fused filament fabrication (FFF) or bound metal deposition (BMD)—has therefore emerged as a cost-effective alternative, producing parts through an extrusion–debinding–sintering (FDMS) process chain. This review critically examines the process physics and manufacturing science of SS316L metal FFF, emphasizing interdependencies between powder morphology, binder chemistry, filament rheology, bead deposition, debinding transport, and sintering densification. Attention is given to defect initiation and evolution, showing how printing-induced interlayer voids and debinding-derived pore networks govern final pore architecture, anisotropy, dimensional accuracy, and mechanical reliability. Typical mechanical property ranges and microstructural characteristics are synthesized in relation to process conditions and post-densification strategies such as hot isostatic pressing. The review further evaluates modeling approaches for extrusion and sintering and highlights the need for standardized reporting. Overall, SS316L metal FFF occupies a scalable niche between prototyping and functional production, with future progress driven by advanced feedstocks, defect-aware simulation, and performance-based design guidelines.