Metal-Based Additive Manufacturing: Innovations in Methods, Applications, Challenges, and Advancements in Material Science

ABSTRACT: Metal-based additive manufacturing (AM) represents a significant advancement in material science, revolutionizing the design, fabrication, and application of metal components. This review examines the material science foundation’s underpinning key AM methods, including Powder Bed Fusion (PBF), Direct Energy Deposition (DED), Binder Jetting, Metal Material Extrusion, and Sheet Lamination. It discusses the material-specific challenges and opportunities these methods offer, particularly in the context of alloy development, powder characteristics, microstructural control, and mechanical performance optimization. Applications of metal AM in industries such as aerospace, automotive, healthcare, energy, and tooling are explored, with a focus on how AM-driven innovations in material design enable lightweight, high-strength, and corrosion-resistant components. Despite its promise, the field faces material-related challenges such as limited AM-compatible alloys, anisotropic mechanical properties, residual stresses, and powder reuse limitations. Future research in material science aims to address these challenges through the development of novel alloys, enhanced process-structure-property relationships, and sustainable material practices. By integrating advances in material science with AM technologies, this review highlights the transformative potential of metal AM in modern manufacturing and its broader implications for material innovation.