Title: Additive manufacturing and 3D printing: advancements, challenges and future directions

Authors: Pushparaj Sunil Warke; Gulab Siraskar; Sonali Shrikant Patil; G. Murali; Anant Sidhappa Kurhade; Shital Y. Solanke; P.S.N. Masthan Vali; Shital Yashwant Waware

Addresses: Department of Mechanical Engineering, Dr. D.Y. Patil Institute of Technology, Pimpri, Pune – 411018, Maharsahtra, India ' Department of Mechanical Engineering, PCET's Pimpri Chinchwad College of Engineering and Research, Ravet, Pune – 412101, Maharashtra, India ' Department of Mechatronics Engineering, Marathwada MitraMandal's Institute of Technology Pune, 411047, SPPU, Pune, Maharashtra, India ' Department of Mechanical Engineering, Koneru Lakshmaiah Education Foundation, Green Fields, Vaddeswaram, 522 502, AP, India ' Department of Mechanical Engineering, Dr. D.Y. Patil Institute of Technology, Pimpri, Pune – 411018, Maharsahtra, India ' Department of Mathematics, School of Science and Humanities, Ramdeobaba University, Ramdeobaba Tekdi, Katol Road, Nagpur – 440013, Maharashtra, India ' Department of Mechanical Engineering, Koneru Lakshmaiah Education Foundation, Green Fields, Vaddeswaram, 522 502, AP, India ' Department of Mechanical Engineering, Dr. D.Y. Patil Institute of Technology, Pimpri, Pune – 411018, Maharsahtra, India

Abstract: Additive manufacturing (AM), commonly referred to as 3D printing, has revolutionised contemporary manufacturing by providing the ability to create complex geometries along with quick prototyping and product customisation in aerospace, automotive, biomedical, and construction domains. It reviews recent developments in multi-material systems, hybrid manufacturing, coupling with artificial intelligence and sustainable designs. It covers advances in functional graded materials, fibre-reinforced composites and 4D printing that enable adaptive and high-performance structures. It also assesses AI-assisted process optimisation, real-time monitoring and predictive modelling for quality improvement and minimisation of material waste. They discuss hybrid manufacturing processes that leverage the strengths of both additive and subtractive techniques to improve dimensional accuracy and superficial topography. Despite these advances, scalability, standardisation, cost control and environmental assessment are still issues. The survey highlights the influential research gaps and prospects toward intelligent, efficient, sustainable manufacturing ecosystems. [Submitted 4 April 2025; Accepted 22 February 2026]

Keywords: additive manufacturing; 3D printing; multi-material fabrication; hybrid manufacturing; sustainable manufacturing; 4D printing.

DOI: 10.1504/IJMR.2026.154549

International Journal of Manufacturing Research, 2026 Vol.20 No.2, pp.193 - 230

Received: 04 Apr 2025
Accepted: 22 Feb 2026
Published online: 03 Jul 2026 *

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