Emerging trends in large format additive manufacturing processes and hybrid techniques

Abstract Large format additive manufacturing (LFAM) technologies are rapidly growing with significant potential for application in multiple technological sectors like aerospace, tooling, automotive, marine, construction, and energy. LFAM processes offer significant advantages including reduced lead time, cost, and material waste, which are further amplified due to the increased volume of the components. This review paper focuses on LFAM technologies with the highest technology readiness level, i.e., metal Directed Energy Deposition (DED), polymer extrusion, and solid-state deposition (i.e. cold spray additive manufacturing (CSAM)). Common system setups, the maximum deposition rate, and the range of processable materials, along with the achievable mechanical properties and geometrical characteristics, are outlined for each technology, both in individual and hybrid manufacturing formats. The main technological challenges are gathered and discussed to highlight the areas that require further development. Finally, the current industrial applications for LFAM technologies and the expected future developments are outlined. This review provides an overview of LFAM technologies’ current status and discusses their potential in improving the manufacturing of complex and large geometries, with a significant reduction in material and energy consumption, while ensuring high-quality and high-performance components.