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<p>Cutting-edge developments in metal additive manufacturing (AM) technologies have redefined engineering boundaries by enabling the production of intricate components at unprecedented levels of customization. Despite these developments, metal AM products typically contain numerous microstructural and surface defects—underscoring the necessity for rigorous post-processing to achieve functional performance and product life cycle. Various post-processing techniques such as (i) heat treatment, (ii) surface finishing, (iii) machining, (iv) support removal, and (v) laser processing have been adapted previously. In this review, the authors provide comprehensive insights into post-processing techniques applied to suppress micro-defects in metal AM-printed parts. Heat treatment is often identified as a primary post-processing technique for removing residual stresses, enhancing structural integrity, and modifying microstructure. Surface finishing via grinding reduces roughness but is sensitive to material properties and process parameters such as wheel speed, feed rate, and cutting depth. Furthermore, polishing decreases the surface roughness even more than grinding. Such as surface finishing and post-processing using geometrically defined machining, ensures high precision and high feed rates, leading to substantial cost reduction. Laser processing has been identified as an emerging post-processing technology used for both surface polishing and surface hardening, often achieving a reduction in roughness. Notably, laser processing techniques possess relatively high adaptability to complex geometries and offer high repeatability and cost-effectiveness. Hybrid Additive-Subtractive Manufacturing (AM-SM) Technologies have been introduced along with their benefits. Finally, Life Cycle Analysis (LCA) on the Integration of AM with post-processing techniques is also explored to understand the economic and environmental impacts of manufacturing. Different life cycle analyses show that energy consumption in AM manufacturing can be reduced up to 50%, with less material waste &lt; 5% compared with traditional manufacturing. AM also reduces transportation emissions by 30% because localized production and on-demand manufacturing minimize the cost by 30–70% for low-volume production.</p> Graphical Abstract <p></p>

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The defect-postprocessing-lifecycle nexus: a critical review of interdependencies in metal additive-subtractive manufacturing

  • 期刊论文

  • 发表日期：

    2025年10月13日

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  • Adnan Javed,
  • Aqib Mashood Khan,
  • Guolong Zhao,
  • Muhammad Jamil,
  • Julius Schoop,
  • Chunjin Wang,
  • Ning He

摘要

Cutting-edge developments in metal additive manufacturing (AM) technologies have redefined engineering boundaries by enabling the production of intricate components at unprecedented levels of customization. Despite these developments, metal AM products typically contain numerous microstructural and surface defects—underscoring the necessity for rigorous post-processing to achieve functional performance and product life cycle. Various post-processing techniques such as (i) heat treatment, (ii) surface finishing, (iii) machining, (iv) support removal, and (v) laser processing have been adapted previously. In this review, the authors provide comprehensive insights into post-processing techniques applied to suppress micro-defects in metal AM-printed parts. Heat treatment is often identified as a primary post-processing technique for removing residual stresses, enhancing structural integrity, and modifying microstructure. Surface finishing via grinding reduces roughness but is sensitive to material properties and process parameters such as wheel speed, feed rate, and cutting depth. Furthermore, polishing decreases the surface roughness even more than grinding. Such as surface finishing and post-processing using geometrically defined machining, ensures high precision and high feed rates, leading to substantial cost reduction. Laser processing has been identified as an emerging post-processing technology used for both surface polishing and surface hardening, often achieving a reduction in roughness. Notably, laser processing techniques possess relatively high adaptability to complex geometries and offer high repeatability and cost-effectiveness. Hybrid Additive-Subtractive Manufacturing (AM-SM) Technologies have been introduced along with their benefits. Finally, Life Cycle Analysis (LCA) on the Integration of AM with post-processing techniques is also explored to understand the economic and environmental impacts of manufacturing. Different life cycle analyses show that energy consumption in AM manufacturing can be reduced up to 50%, with less material waste < 5% compared with traditional manufacturing. AM also reduces transportation emissions by 30% because localized production and on-demand manufacturing minimize the cost by 30–70% for low-volume production.

Graphical Abstract