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<p>Additive manufacturing (AM) has transformed polymer matrix composites (PMCs) into processes and materials that are sustainable, lightweight and high-performing for a multitude of applications. This review presents a comprehensive study on the fabrication of PMCs, hence covering material choices, reinforcement mechanisms and performance evaluations. A study of metals composites, ceramics composites, carbon based materials and biocomposites highlights the benefits and drawbacks of every material type. Main challenges are posed by the dispersion of reinforcements, processing limitations and sustainability of materials, while some emerging solutions include the utilization of machine learning (ML) and automated manufacturing. The review emphasises the combined consequence of AI optimization, multi-axis printing and bio-based reinforcements on mechanical, thermal and electrical properties. Solutions to these challenges will prepare PMCs printed through 3D for strategic importance in the aerospace, biomedical, automotive and defense industries, propelling the drive for sustainable and high-performing composite materials.</p> Graphical Abstract <p></p>

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Sustainable 3D Printing of Polymer Composites in Material Selection and Performance Evaluation Aspects

  • 期刊论文

  • 发表日期：

    2026年5月27日

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  • Praveen,
  • Rajeev Saha,
  • Sandeep Grover

摘要

Additive manufacturing (AM) has transformed polymer matrix composites (PMCs) into processes and materials that are sustainable, lightweight and high-performing for a multitude of applications. This review presents a comprehensive study on the fabrication of PMCs, hence covering material choices, reinforcement mechanisms and performance evaluations. A study of metals composites, ceramics composites, carbon based materials and biocomposites highlights the benefits and drawbacks of every material type. Main challenges are posed by the dispersion of reinforcements, processing limitations and sustainability of materials, while some emerging solutions include the utilization of machine learning (ML) and automated manufacturing. The review emphasises the combined consequence of AI optimization, multi-axis printing and bio-based reinforcements on mechanical, thermal and electrical properties. Solutions to these challenges will prepare PMCs printed through 3D for strategic importance in the aerospace, biomedical, automotive and defense industries, propelling the drive for sustainable and high-performing composite materials.

Graphical Abstract