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<p>The latest developments in the three-dimensional (3D) printing technology have rendered lightweight, high-performance, and application-specific components available. The paper discusses the major 3D printing techniques used in the manufacture of polymer composites: Stereolithography (SLA), Direct Ink Writing (DIW), Selective Laser Sintering (SLS), and Fused Deposition Modelling (FDM). This research paper is specializing in new materials that enhance performance in terms of heat resistance, strength, and quality in general. These materials include thermoplastics, thermosets, nanocomposites and continuous fibre reinforcers. The literature review is conducted in a systematic manner, covering the years 2015 to 2025 according to the PRISMA framework, and it focuses on the progress in tensile strength, surface finish, and structural reliability. Comparison of carbon fibre, graphene and ceramic based composites illustrates advanced methods of reinforcement. The review also looks at the emerging and hybrid methods where several processes are combined to increase accuracy, material compatibility and performance. The problems it defines include inconsistent properties, high energy use, material constraints, and sustainability, as well as analyzes future developments, namely 4D printing, artificial intelligence to improve processes, smart polymers, and bio-based composites. The originality of this review is that it is a PRISMA-based systematic synthesis with a cross-comparative analysis of the material, processes, and performance indices and an integrated trade-off analysis of the benefits and restrictions of various 3D printing techniques. In contrast to the current reviews, which concentrate on either material innovations or process methods separately, the paper is a coherent framework of material process application relationships and in addition, it offers the emergent technology shifts towards AI-driven and sustainable additive manufacturing systems.This comprehensive synthesis enables innovation and informed decision making within high performance industrial, biomedical and aerospace applications.</p> Graphical Abstract <p></p>

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Recent Advances in 3D Printing of Polymer Composites: Materials, Processing Techniques, and Emerging Applications

  • 期刊论文

  • 发表日期：

    2026年6月19日

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  • Praveen,
  • Rajeev Saha,
  • Sandeep Grover

摘要

The latest developments in the three-dimensional (3D) printing technology have rendered lightweight, high-performance, and application-specific components available. The paper discusses the major 3D printing techniques used in the manufacture of polymer composites: Stereolithography (SLA), Direct Ink Writing (DIW), Selective Laser Sintering (SLS), and Fused Deposition Modelling (FDM). This research paper is specializing in new materials that enhance performance in terms of heat resistance, strength, and quality in general. These materials include thermoplastics, thermosets, nanocomposites and continuous fibre reinforcers. The literature review is conducted in a systematic manner, covering the years 2015 to 2025 according to the PRISMA framework, and it focuses on the progress in tensile strength, surface finish, and structural reliability. Comparison of carbon fibre, graphene and ceramic based composites illustrates advanced methods of reinforcement. The review also looks at the emerging and hybrid methods where several processes are combined to increase accuracy, material compatibility and performance. The problems it defines include inconsistent properties, high energy use, material constraints, and sustainability, as well as analyzes future developments, namely 4D printing, artificial intelligence to improve processes, smart polymers, and bio-based composites. The originality of this review is that it is a PRISMA-based systematic synthesis with a cross-comparative analysis of the material, processes, and performance indices and an integrated trade-off analysis of the benefits and restrictions of various 3D printing techniques. In contrast to the current reviews, which concentrate on either material innovations or process methods separately, the paper is a coherent framework of material process application relationships and in addition, it offers the emergent technology shifts towards AI-driven and sustainable additive manufacturing systems.This comprehensive synthesis enables innovation and informed decision making within high performance industrial, biomedical and aerospace applications.

Graphical Abstract