Advancements and Limitations in 3D Printing Materials and Technologies: A Critical Review

Abstract

3D printing has revolutionized various industries by enabling the production of complex designs and shapes. Recently, the potential of new materials in 3D printing has led to an exponential increase in the technology's applications. However, despite these advancements, the technology still faces significant challenges, including high costs, low printing speeds, limited part sizes, and strength. This paper critically reviews the recent trends in 3D printing technology, with a particular focus on the materials and their applications in the manufacturing industry. The paper highlights the need for further development of 3D printing technology to overcome its limitations. It also summarizes the research conducted by experts in this field, including their focuses, techniques, and limitations. By providing a comprehensive overview of the recent trends in 3D printing, this review aims to provide valuable insights into the technology's prospects.

Keywords: 3D printing; additive manufacturing; engineering applications; materials.

Figure 1

Different types of polymer materials derived from (A) polylactic acid (PLA)—food containers; (B) acrylonitrile butadiene styrene (ABS)—Lego blocks; (C) polyethylene terephthalate (PET)—water bottles; (D) thermoplastic elastomers (TPE)—airless tires; (E) polyamide (PA) or nylon—rope; (F) polycarbonate (PC)—rolling suitcase.

Figure 2

Some additional types of polymer materials derived from (A) high-impact polystyrene (HIPS)—stationery trays; (B) polyvinyl alcohol (PVA)—food wrap; (C) acrylonitrile styrene acrylate (ASA)—drain pipes and fittings; (D) polypropylene (PP)—food containers; (E) polycarbonate ABS alloy (PC-ABS)—glove box; (F) gears.

Figure 3

The most popular and trending metal 3D printing technologies and their applications. (A) Selective Laser Melting (SLM) 3D printer and (B) An Impeller 3D printed on Selective Laser Melting machine. (C) Fused Deposition Modeling (FDM) 3D printer and (D) A Sprocket Gear 3D printed using Fused Deposition Modeling Method. (E) Laser Metal Wire Deposition (LMWD) 6-dimensional robotic arm 3D printer and (F) A Rocket body 3D printed using this Laser Metal Wire Deposition 6-dimensional robotic arm.

Figure 4

Fiber-reinforced composite 3D printing process. (a) actual scene, (b) printed specimen and (c) printing process [45,46]. Reprinted under the Creative Commons (CC) License (CC BY 4.0).

Figure 5

The bioprinting process.

Figure 6

Major applications of 3D printing.

Figure 7

Samples of aerospace applications. (A) First 3D printer taken to International Space Station, (B) Fabrication and Testing of various parts required in Space Station [51]. Reprinted under the Creative Commons (CC) License (CC BY 4.0).

Figure 8

Scaffolds built of metal powders and manufactured via SLM 3D printing.

Figure 9

Simulated 3D-printed insertion tool composed of biopolymer material [60]. Reprinted under the Creative Commons (CC) License (CC BY 4.0).

Figure 10

The concept of 6D printing [67]. Reprinted under the Creative Commons (CC) License (CC BY 4.0).