Field assisted additive manufacturing for polymers and metals: materials and methods

Additive manufacturing (AM) has emerged as a transformative technology capable of fabricating complex geometries and multi-material structures across various industries. Despite its potential, challenges persist in terms of limited material selection, anisotropic properties, and achieving functional microstructures in polymer and metal composites. Field-assisted additive manufacturing (FAAM) employs external fields like acoustic, magnetic, and electric fields. It has shown promise in addressing these limitations by controlling filler orientation and concentration in polymeric composites and improving surface finish and microstructure in metals. This review paper provides a comprehensive analysis of the state-of-the-art FAAM processes for polymer and metal composites, focusing on material compatibility, the mechanics of each field, and their integration with AM technologies as well as current applications, limitations, and potential future directions in the development of FAAM processes. Enhancing FAAM process understanding can create tailored anisotropic composites, enabling innovative applications in aerospace, automotive, biomedical fields, and beyond.

Automated summary

Additive manufacturing (AM) is a transformative technology that can fabricate complex geometries and multi-material structures across industries. Field-assisted additive manufacturing (FAAM) utilizes external fields to control materials, addressing limitations such as limited material selection and anisotropic properties. This review analyzes FAAM processes for polymer and metal composites, focusing on material compatibility, field mechanics, integration with AM technologies, current applications, limitations, and potential future directions.