Fused Deposition Modelling in Additive Manufacturing: A Comprehensive Review of Polymer-Based Processes, Properties, and Applications

Fused deposition modeling (FDM) is the preferred approach in polymer additive manufacturing (AM) owing to its design flexibility, the availability and affordability of materials, and printing consistency and performance constrained by processing-degradation interactions. This review focuses on FDM, a technology that demonstrates outstanding efficiency due to its adaptability and facilitates productivity in the rapid prototyping of complicated geometries. The microstructure, impact toughness, tensile strength, and wear resistance of the produced components may be studied by examining the influence of variables, viz., infill density, printing speed, layer thickness, nozzle diameter, and extrusion temperature. Investigators take a comprehensive look at thermal deterioration and how post-processing changes its attributes. The performance-enhancing effects of strands modified with nanomaterials and the microstructural development of printed components are also highlighted. The benefits of using machine learning on FDM for fault estimation, closed-loop monitoring, and attribute-targeted inverse design are also discussed. The reusability of FDM-printed components and their impact on the green economy are evaluated. In addition, several applications of functionally dense matrix components with tight tolerances are discussed, along with possible avenues for future study in state-of-the-art methods such as smart polymers and 4D printing.