Advancements and Challenges in Additively Manufactured Functionally Graded Materials: A Comprehensive Review

Abstract

This paper thoroughly examines the advancements and challenges in the field of additively manufactured Functionally Graded Materials (FGMs). It delves into conceptual approaches for FGM design, various manufacturing techniques, and the materials employed in their fabrication using additive manufacturing (AM) technologies. This paper explores the applications of FGMs in diverse fields, including structural engineering, automotive, biomedical engineering, soft robotics, electronics, 4D printing, and metamaterials. Critical issues and challenges associated with FGMs are meticulously analyzed, addressing concerns related to production and performance. Moreover, this paper forecasts future trends in FGM development, highlighting potential impacts on diverse industries. The concluding section summarizes key findings, emphasizing the significance of FGMs in the context of AM technologies. This review provides valuable insights to researchers, practitioners, and stakeholders, enhancing their understanding of FGMs and their role in the evolving landscape of AM.

Untapped Opportunities in Additive Manufacturing with Metals: From New and Graded Materials to Post-Processing

“…Hence, special measures are necessary for the design step, which will be discussed further. Table 2 summarizes the compatibility of different base alloys comparatively from three aspects of "intermetallic formation and solubility limitations," the "mismatch of thermal property," and "other metallurgical effects," based on the literature [71][72][73]. In an electrophotographic-based dual powders dispenser (Figure 19c), the powder particles are accurately placed on a cylindrical mesh via a micro-airflow, and the deposition process is carried out using a (laser) heat source by blowing them off the mesh onto the platform.…”

“…Hence, special measures are necessary for the design step, which will be discussed further. Table 2 summarizes the compatibility of different base alloys comparatively from three aspects of "intermetallic formation and solubility limitations," the "mismatch of thermal property," and "other metallurgical effects," based on the literature [71][72][73]. Figure 21 illustrates some compositional gradient designs proposed in AM.…”