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Materials Science in Additive Manufacturing Functional materials for AM

These polymers, ranging from photo-curable resins
to thermoplastics and viscous polymer inks, find
applications across diverse areas, including medical,
aerospace, automotive, electronics, soft robotics, energy,
environmental, and industrial fields, depending on their
specific characteristics. 12,13 Moreover, recent research is
exploring the potential of polymers for 4D printing, where
they can respond to stimuli such as temperature, light,
electric fields, magnetic fields, and moisture, resulting in
changes in shape or properties over time. 14,15 The versatility
and adaptability of polymer materials render them
highly desirable for AM, especially when integrated with
functional materials to enable a wide range of applications.
AM using functional materials has emerged as a
critical area of research in the manufacturing industry.
The use of polymer-based functional materials in AM
offers significant advantages due to ease of processing and
low manufacturing temperatures. By combining various
functional materials with polymer matrices, it becomes
possible to enhance the characteristics and functionalities Figure 1. Overview of functional materials for additive manufacturing
of polymers, facilitating the fabrication of components techniques and applications.
with properties such as magnetic, actuating, and electrical
conductivity. Furthermore, ongoing research is exploring strategies, material selections, and application prospects
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the fabrication of parts with properties such as piezoelectric are provided to foster a deeper understanding of AM
and thermoelectric behavior by leveraging multi-material technology and stimulate further innovation toward the
manufacturing capabilities. 16,17 The development of AM realization of advanced functional devices and systems.
technology using functional and high-performance
materials unlocks diverse applications across various 2. AM methods for functional materials
industries, ranging from electronics engineering to medical According to American Society for Testing and Materials
purposes such as artificial organs and medical robotics. 18,19 standards, the AM of functional polymer materials can be
These research efforts underscore the innovative classified into several categories: material extrusion, vat
advancements driven by AM with functional materials in photopolymerization, binder jetting, powder bed fusion
the manufacturing industry and are expected to contribute (PBF), and material jetting. Each AM technology has its
to enhancing manufacturing process efficiency and unique manufacturing process and compatible materials,
product performance. with the suitable technology varying depending on the
This review aims to comprehensively investigate state- required functional characteristics and polymer types.
of-the-art research efforts on AM of functional materials These classifications and characteristics are summarized in
integrated with polymer matrices. It systematically Table 1.
categorizes AM systems and methodologies used for 2.1. Material extrusion
polymer-based functional materials. Subsequently, it
summarizes notable studies that fabricate various functional Material extrusion is currently the most commonly used
materials or structures, such as magnetic, metal powder, AM method, forming layers by extruding thermoplastic or
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perovskite, piezoelectric, and thermoelectric materials, liquid-state materials through small nozzles. While this
exploring their applications in fabricating multifunctional method may have relatively lower resolution and accuracy,
components and devices. Ultimately, by studying and its affordability and ability to mix with various materials
analyzing the latest developments in polymer-based AM of make it widely utilized, especially in the manufacturing of
functional materials, this review seeks to provide insights functional polymers. An example of a material extrusion
into current challenges, future directions, and potential AM method commonly used for polymers is depicted in
innovations in the rapidly growing field of functional AM. Figure 2A.
Figure 1 provides an overview of functional materials Fused deposition modeling (FDM) is a 3D printing
for AM techniques and applications. Descriptions of key technique in which molten thermoplastic material is

Volume 3 Issue 2 (2024) 2 doi: 10.36922/msam.3323