Recent Advances in Additive Manufacturing: A Review of Current Developments and Future Directions

Abstract

Additive manufacturing (AM), often referred to as 3D printing, has seen significant advances over the last few years. Through extensive research covering a wide range of industries from automotive and aerospace to healthcare, AM comes with the advantage of reduced manufacturing costs and ease of transition from design to real prototype. This review paper navigates the landscape of the AM process to highlight the latest findings in terms of process, materials, and applications by analyzing publications between 2022 and 2025. A particular focus is given to the integration of new materials including high-performance polymers and bio-based composites, types of printing materials that can enhance the performance and durability of 3D printing processes. In addition, the paper examines advances in printing technologies, including multi-material and large-format printing, as well as the integration of artificial intelligence for process optimization and quality control. Considering these advances, critical challenges such as the productivity, high cost, limited material options, and ethical concerns over intellectual property are also addressed. By synthesizing current trends and assessing future directions, while considering a critical view, this study aims to inform researchers and industry stockholders about the evolving additive manufacturing landscape and the opportunities and obstacles on the horizon.