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<p>This review article explores the evolution and current state of metal additive manufacturing (AM), highlighting its transformative influence that spans multiple industries, such as aerospace, automotive, healthcare, and civil engineering. The paper discusses the progression from traditional 3D printing to advanced techniques such as 4D, 5D, and 6D printing, emphasizing their unique capabilities and applications. Key materials, including titanium, aluminum, nickel-based superalloys, high-entropy alloys, and magnesium alloys<b>,</b> are examined for their specific processing challenges and solutions in AM. The integration of hybrid manufacturing techniques is also addressed, showcasing how hybrid manufacturing techniques can improve the performance and reliability of 3D-printed components. The review identifies critical scientific challenges in metal additive manufacturing, such as microstructural control, mechanical property optimization, and defect management, and proposes potential solutions and future research directions. By providing a comprehensive overview of the unique advantages and ongoing challenges in this field, this work aims to inform and support researchers and engineers working to advance the capabilities of metal additive manufacturing.</p>

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Challenges, Solutions, and Future Perspectives in Metal Additive Manufacturing: A Review

  • 期刊论文

  • 发表日期：

    2026年3月4日

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  • Mingzhang Chen,
  • XunChen Liu,
  • Yilun Wang,
  • Zhiheng Hu,
  • Lin Hua,
  • Zeqi Hu,
  • Xunpeng Qin,
  • Yitao Huang

摘要

This review article explores the evolution and current state of metal additive manufacturing (AM), highlighting its transformative influence that spans multiple industries, such as aerospace, automotive, healthcare, and civil engineering. The paper discusses the progression from traditional 3D printing to advanced techniques such as 4D, 5D, and 6D printing, emphasizing their unique capabilities and applications. Key materials, including titanium, aluminum, nickel-based superalloys, high-entropy alloys, and magnesium alloys, are examined for their specific processing challenges and solutions in AM. The integration of hybrid manufacturing techniques is also addressed, showcasing how hybrid manufacturing techniques can improve the performance and reliability of 3D-printed components. The review identifies critical scientific challenges in metal additive manufacturing, such as microstructural control, mechanical property optimization, and defect management, and proposes potential solutions and future research directions. By providing a comprehensive overview of the unique advantages and ongoing challenges in this field, this work aims to inform and support researchers and engineers working to advance the capabilities of metal additive manufacturing.