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<p>Additive manufacturing (AM) is increasingly used to produce complex components across various industries. However, porosity remains a critical factor influencing the structural integrity and performance of AM parts. This review presents a comprehensive analysis of how porosity, whether inherent or process-induced, affects mechanical, thermal, electrical, and fatigue properties in both metals and polymers. Detailed attention is given to the mechanisms of strength reduction, anisotropy, failure under cyclic loading, and performance degradation due to pore characteristics such as size, shape, distribution, and location. Furthermore, the review explores theoretical and numerical models for estimating fatigue life, including Kitagawa–Takahashi and Murakami approaches, alongside the impact of porosity on conductivity metrics governed by classical and modified models. These insights are crucial for engineers and researchers seeking to design robust AM components that account for inevitable or controlled porosity levels.</p>

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Porosity in additive manufacturing: influence on mechanical, thermal, and electrical properties—a review

  • 期刊论文

  • 发表日期：

    2025年9月8日

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  • Suhas Alkunte,
  • Madhur Gupta,
  • Kishor Shingare,
  • Nitin More,
  • Abhijeet Mali,
  • Nikhil Ingle,
  • Swapnil Nalawade,
  • Anas Ullah Khan,
  • Nilima Sinha,
  • Kin Liao,
  • Ismail Fidan

摘要

Additive manufacturing (AM) is increasingly used to produce complex components across various industries. However, porosity remains a critical factor influencing the structural integrity and performance of AM parts. This review presents a comprehensive analysis of how porosity, whether inherent or process-induced, affects mechanical, thermal, electrical, and fatigue properties in both metals and polymers. Detailed attention is given to the mechanisms of strength reduction, anisotropy, failure under cyclic loading, and performance degradation due to pore characteristics such as size, shape, distribution, and location. Furthermore, the review explores theoretical and numerical models for estimating fatigue life, including Kitagawa–Takahashi and Murakami approaches, alongside the impact of porosity on conductivity metrics governed by classical and modified models. These insights are crucial for engineers and researchers seeking to design robust AM components that account for inevitable or controlled porosity levels.