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<p>Metal Additive Manufacturing (MAM) has emerged as a transformative technology, enabling the fabrication of complex metallic components with enhanced design flexibility and reduced material waste. This review provides a critical overview of the fundamental principles, recent advancements, and ongoing challenges associated with contemporary MAM processes. It begins with a classification of major MAM techniques, followed by a comprehensive discussion of common defects, including surface irregularities, microstructural heterogeneities, and mechanical inconsistencies. Particular emphasis is placed on post-processing strategies to improve surface finish, dimensional accuracy, and the uniformity of mechanical and microstructural properties. Furthermore, the review highlights the need for standardized protocols, robust material databases, and design guidelines to facilitate wider industrial adoption. Finally, the paper concludes by outlining the significant potential of MAM to revolutionize major sectors, including the aerospace, automotive, biomedical, and tooling industries.</p>

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A review on recent developments, trends, and critical challenges of metal additive manufacturing processes

  • 期刊论文

  • 发表日期：

    2026年8月4日

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  • Harpal,
  • Gurraj Singh,
  • Munish Kumar Gupta

摘要

Metal Additive Manufacturing (MAM) has emerged as a transformative technology, enabling the fabrication of complex metallic components with enhanced design flexibility and reduced material waste. This review provides a critical overview of the fundamental principles, recent advancements, and ongoing challenges associated with contemporary MAM processes. It begins with a classification of major MAM techniques, followed by a comprehensive discussion of common defects, including surface irregularities, microstructural heterogeneities, and mechanical inconsistencies. Particular emphasis is placed on post-processing strategies to improve surface finish, dimensional accuracy, and the uniformity of mechanical and microstructural properties. Furthermore, the review highlights the need for standardized protocols, robust material databases, and design guidelines to facilitate wider industrial adoption. Finally, the paper concludes by outlining the significant potential of MAM to revolutionize major sectors, including the aerospace, automotive, biomedical, and tooling industries.