Review of Additive Manufacturing Technology: Fundamentals and Processing Techniques
DOI:
https://doi.org/10.33003/fjs-2026-1011-5422Keywords:
Additive Manufacturing, Layer-by-Layer Deposition, 3D Object, DefectsAbstract
Consequence to the challenges of conventional materials processing and manufacturing technologies, scientists and engineers are everyday searching for new technologies to improve or replace the existing ones. Additive manufacturing is one of the promising technologies that show the potential in replacing conventional manufacturing processes. This study reviewed the fundamentals and processing techniques of various additive manufacturing technologies such as, directed energy deposition, powder bed fusion, material jetting, etc. Basic working principles, sources of energy, raw and forms of materials as well as process parameters of the various additive manufacturing processes were studied. Recent original works were studied and relevant findings were expatiated. Energy ranges of the various additive manufacturing processes were studied. It is understood from the findings that despite numerous benefits of additive manufacturing various defects still pose processing problems, and therefore mitigation measures such as optimization and use of hybrid sensor defects detection were highlighted for future trend of research. It is further concluded that the integration of artificial intelligence with additive manufacturing is paramount for overall enhancing the performance of additive manufacturing for wider applications in industry 4.0 and 5.0.
References
Reference
Adoyi, J. P., Hassan, S., Otor, S., & Adeyelu, A. (2026). A multi-hybrid framework for image augmentation in a randomized setting. FUDMA Journal of Science (FJS), 10(2), 364–374. https://doi.org/10.33003/fjs-2026-1002-4338
Albahadli, N. A., Jilabi, A., & Aljuboori, H. (2025). Wire arc additive manufacturing of steels. Kufa Journal of Engineering, 17(1), 190–203. https://doi.org/10.30572/2018/KJE/170111
Amir, B. (2022). Laser welding and additive manufacturing of duplex stainless steel: Properties and microstructural characterization.
Aydin, G., Bemergo, M., Hogstrom, M., & Selte, A. (2023). Influence of laser metal deposition process parameters on precipitation hardening stainless steel. Welding in the World.
Baumers, M. (2012). Economic aspects of additive manufacturing: Benefits, costs and energy consumption (Doctoral dissertation, Loughborough University).
Bisht, A. K., & Vaishya, R. O. (2022). A comprehensive detailed review of additive manufacturing (3D printing) processes, applications and future aspects. International Journal of Research Publication and Review, 3(6), 4095–4105.
Bomias, G. (2022). Thermal and residual stress modelling of functionally graded deposits using PTAAM (Master’s thesis, University of Alberta).
Caiazzo, F., & Alfieri, V. (2021). Optimization of laser beam welding of steel parts made by additive manufacturing. The International Journal of Advanced Manufacturing Technology, 114, 3123–3136. https://doi.org/10.1007/S00170-021-07039-w
Costa, J. M., Ferreira, A., Junior, M. N., & Reisi, M. (2018). Metal additive manufacturing joining with dissimilar materials. In Proceedings of the 2nd International Conference on Materials Design and Application. FEUP.
Cranell, R. D., Bernalte, E., & Banks, C. E. (2026). Advances in additive manufacturing electrochemistry. Chemical Reviews. https://doi.org/10.1021/acs.chemrev.5c00984
Gibson, I., Rosen, D., Stucker, B., & Khorasani, A. (2021). Sheet lamination. In Additive Manufacturing Technologies (pp. 253–283).
Gulcan, O., Gunaydin, K., & Tamer, A. (2021). The state of the art of material jetting: A critical review. Polymers, 13, 2029. https://doi.org/10.3390/polym13162829
Gupta, R., Dalakoti, M., & Narashimhulu, A. (2020). A critical review of process parameters in laminated object manufacturing process. In Advances in Materials Engineering and Manufacturing Process (pp. 31–39). https://doi.org/10.1007/978-981-15-4331-9_3
Hadi, R. M., & Taha, Z. A. (2022). Effect of SiC addition on microhardness and relative density during SLM of 316L stainless steel. Journal of Engineering. https://doi.org/10.1155/2022/3552675
Hasanov, S., Alkunte, S., Rajeshirke, M., Gupta, A., Huseynov, O., Fidan, I., Alifui-Segbaya, F., & Rennie, A. (2022). Review on additive manufacturing of multi-material parts: Progress and challenges. Journal of Manufacturing and Materials Processing, 6(4). https://doi.org/10.3390/jmmp6010004
Hejripour, F., Farrokh, B., Mark, H., & Daryush, K. A. (2019). Thermal modelling and characterization of wire arc additive manufactured duplex stainless steel. Journal of Materials Processing Technology, 58–71.
Jokisch, T., Marko, A., Gook, S., Ustundag, O., Gunmenyuk, A., & Rethmeier, M. (2019). Laser welding of SLM-manufactured tubes made of IN625 and IN718. Materials, 12.
Ki, M., Du, W., Elwany, A., Pei, Z., & Ma, C. Metal binder jetting additive manufacturing: A literature review. Journal of Manufacturing Science and Engineering.
Liu, P., Zhu, Z., & Jia, L. (2026). Powder-based additive manufacturing of Ti2AlNb alloys: A review of processes, microstructures and mechanical properties. High-Temperature Materials, 3(2), 10010. https://doi.org/10.70322/htm.2026.10010
Matilainen, V., Pekkarinen, J., & Salminen, A. (2016). Weldability of additive manufactured stainless steel. Physics Procedia, 83.
Megahed, S., Koch, R., & Schleifenbaum, J. H. (2022). Laser powder bed fusion tool repair: Statistical analysis of 1.2343/H11 tool steel process parameters and microstructural analysis of the repair interface. Journal of Manufacturing and Materials Processing, 6, 139. https://doi.org/10.3390/jmmp6060139
Miller, N., Sung, J., & Chung, H. (2026). Defect detection and optimization for additive manufacturing powered by artificial intelligence: A review. International Journal of Precision Engineering and Manufacturing, 4(1), 1–43.
Mohyla, P., Hajnys, J., Sternadelova, K., Lucier, K., Pagac, M., Konecna, K., & Krpec, P. (2023). Analysis of welded joint properties on an AISI 316L stainless steel tube manufactured by SLM technology. Materials, 13, 4362.
Mokhtari, M., Pommier, P., Balcaen, J., & Alexis, J. (2022). Laser welding of AISI 316L stainless steel produced by additive manufacturing or by conventional processes. Journal of Manufacturing and Materials Processing, 5(136). https://doi.org/10.3390/jmmp5040136
Mostafaei, A., Elliott, A. M., Barnes, J., Li, F., Tan, W., Cramer, C. L., Nandwana, P., & Chmielus, M. (2020). Binder jet 3D printing: Process parameters and challenges. Progress in Materials Science.
Nohut, S., & Schwentenwein, M. (2022). Vat photopolymerization additive manufacturing of functionally graded materials: A review. Journal of Manufacturing and Materials Processing, 6, 17. https://doi.org/10.3390/jmmp010017
Oska, B. (2022). Fatigue and microstructural study of a 316L austenitic stainless steel marine component produced by WAAM (Degree project, Uppsala University).
Ostolaza, M., Arrizubieta, J., Lamikiz, A., Plaza, S., & Ortega, N. (2023). Latest developments in manufacturing metal matrix composites and functionally graded materials through additive manufacturing: A state-of-the-art review. Materials, 16, 1746. https://doi.org/10.3390/ma16041746
Ramachandiran, N. (2023). Structure-property correlation in additive manufactured Ti-553 components (Doctoral dissertation, University of Waterloo).
Rodrigues, T. A., Duarte, V., Avila, J. A., Santos, G. T., Miranda, R. M., & Oliveira, J. P. Wire and arc additive manufacturing of HSLA steel: Effect of thermal cycles on microstructure and mechanical properties.
Salari, F., Bosetti, P., & Sglavo, V. M. (2022). Binder jetting 3D printing of magnesium oxychloride cement-based materials: Parametric analysis of manufacturing factors. Journal of Manufacturing and Materials Processing, 6, 86. https://doi.org/10.3390/jmmp6040086
Samoilenko, M., Lanik, G., & Brailovski, V. (2021). Towards the determination of machining allowances and surface roughness of 3D-printed parts subjected to abrasive flow machining. Journal of Manufacturing and Materials Processing, 5, 111. https://doi.org/10.3390/jmmp5040111
Satoodeh, K. (2021). Dissimilar welding between piping and valves in the offshore oil and gas industry. Welding International, 36(1–3). https://doi.org/10.1080/09507116.2021.1919495
Savchenko, B., Siva, N., Beloshenko, V., Debulyuk, B., Slieptsov, A., & Volzniak, L. (2022). New approach for extrusion additive manufacturing of soft and elastic articles from liquid PVC-based consumable materials. Polymers, 14, 4683.
Singh, A., Math, T., Dommeti, S. G., & Sekar, S. (2022). Bulk fabrication of SS410 material using cold transfer-based WAAM process at optimized parameters: Microstructural and property evaluation. Machines, 10, 1136. https://doi.org/10.3390/machines10121136
Sinha, A., Swain, B., Behera, A., Mallick, P., Samal, S. K., Vishwanatha, H. M., & Behera, A. (2022). A review on the processing of aero-turbine blades using 3D printing techniques. Journal of Manufacturing and Materials Processing, 6, 16. https://doi.org/10.3390/jmmp6010016
Sireesha, M., Lee, J., Kiran, A. S. K., Babu, V. J., Lee, B. T., & Ramakrishna, S. (2018). A review on additive manufacturing and its way into the oil and gas industry. RSC Advances, 8, 22460–22468.
Song, K., Lin, Z., Fa, Y., Zhao, Y., Zhu, Z., Ya, W., Sun, Z., & You, X. (2023). Microstructure and mechanical properties of HSLA steel thin-wall fabrication by WAAM. Metals, 13, 764. https://doi.org/10.3390/met13040764
Sun, C., Wang, Y., McMurtrey, M. D., Jerred, N. D., Liou, F., & Li, J. (2021). Additive manufacturing for energy: A review. Applied Energy, 282.
Uralde, V., Suarez, A., Aldalur, E., Veiga, F., & Ballesteros, T. (2023). Wall fabrication by direct energy deposition combining mild steel (ER70) and stainless steel (316L): Microstructure and mechanical properties. Materials, 15, 5828. https://doi.org/10.3390/ma15175828
Wiikinkoski, O. H. (2022). Design and construction of a high-frequency ultrasonic vibration platform for grain refinement during direct energy deposition additive manufacturing (Master’s thesis, Aalto University).
Zhang, X., & Liou, F. (2021). Introduction to additive manufacturing.
Downloads
Published
Issue
Section
Categories
License
Copyright (c) 2026 Misbahu Hayatu, Aishat Ometere Salawu, Kamilu Adeyemi Bello
This work is licensed under a Creative Commons Attribution 4.0 International License.
