[Paper Review] A Review of Multi-material and Composite Parts Production by Modified Additive Manufacturing Methods

Maziar Toursangsaraki|arXiv (Cornell University)|Jun 12, 2018

Additive Manufacturing and 3D Printing TechnologiesEngineering156 references16 citations

TL;DR

This paper reviews modified additive manufacturing (AM) methods enabling the production of multi-material and composite parts by integrating diverse materials within a single fabrication process. It highlights process modifications that enhance material versatility, reduce part count through integrated design, and improve functional performance and weight efficiency in complex components.

ABSTRACT

Aside from the capability of additive manufacturing (AM) methods in fabricating components with complex geometries, two crucial potentials of this manufacturing process that are worth mentioning are its flexibility in being combined with other production methods as well as use of a variety of materials in a single production platform to make multi-material and composite products. Implementation of multiple materials in integrated structures has been shown to improve the functionality, weight reduction and, by merging the assembly and production into one stage, modify the manufacturing processes. Different approaches towards modification of AM processes aimed to reach multi-material or composite parts are being reviewed in this paper.

Motivation & Objective

• To examine how additive manufacturing (AM) can be modified to produce multi-material and composite components with enhanced functionality.
• To identify process modifications that enable the integration of multiple materials within a single AM platform.
• To analyze the impact of multi-material AM on part consolidation, weight reduction, and manufacturing efficiency.
• To evaluate the current state of technology and identify key challenges in material compatibility and process control.
• To provide a comprehensive overview of emerging techniques for producing functional, hybrid-structured parts using modified AM methods.

Proposed method

• Systematic review of modified additive manufacturing processes focused on multi-material and composite part production.
• Analysis of hybrid AM techniques combining traditional AM with secondary processes such as material deposition, post-processing, and in-situ material blending.
• Evaluation of material deposition strategies including dual-nozzle systems, multi-material nozzles, and sequential layering with different feedstocks.
• Examination of process parameters affecting interfacial bonding, dimensional accuracy, and mechanical integrity in multi-material AM.
• Review of case studies demonstrating successful integration of dissimilar materials (e.g., metals, polymers, ceramics) in single components.
• Assessment of technological limitations such as material mismatch, thermal expansion differences, and process scalability.

Experimental results

Research questions

• RQ1 How can additive manufacturing be modified to enable the co-deposition of multiple materials in a single build process?
• RQ2 What are the key technical challenges in achieving strong interfacial bonding between dissimilar materials in AM-produced composites?
• RQ3 In what ways do modified AM processes improve functional performance and reduce part count compared to conventional manufacturing?
• RQ4 How do process parameters influence the mechanical and thermal properties of multi-material AM components?
• RQ5 What are the current limitations in material compatibility and scalability for industrial adoption of multi-material AM?

Key findings

• Modified AM methods enable the fabrication of complex, multi-material components with improved functional performance and reduced assembly needs.
• Integration of dissimilar materials such as metals, polymers, and ceramics in a single build process has been demonstrated, enhancing design freedom and part efficiency.
• The consolidation of multiple parts into a single AM-manufactured component leads to significant weight reduction and improved structural integrity.
• Interfacial bonding quality remains a critical challenge, particularly when joining materials with large differences in thermal expansion and melting behavior.
• Dual-nozzle and multi-material deposition systems show promise in achieving controlled material distribution and graded properties.
• Despite progress, challenges in material compatibility, process control, and scalability limit widespread industrial adoption of multi-material AM.