Linking Process Parameters, Structure, and Properties in Material Extrusion Additive Manufacturing of Polymers and Composites: A Review

This review investigates how process parameters and material choices influence the mechanical performance of parts produced by material extrusion additive manufacturing, with a particular focus on Material Extrusion (ME). Through a systematic bibliometric analysis of literature between 2015 and 2025, the study identifies key factors affecting mechanical strength, anisotropy, and structural reliability, including printing temperature, speed, orientation, layer thickness, and interlayer bonding. Emphasis is placed on emerging techniques such as 4D printing, fiber-reinforced composites, and novel monitoring methods like real-time vibration sensing and thermal imaging, which offer promising pathways to improve part performance and process stability. Three research questions guide the analysis: (1) how printing parameters affect micro- to macrostructure and failure behavior, (2) how optimization strategies enhance part quality, and (3) how material and process selection aligns with functional requirements. The review highlights both advances and persistent limitations in process control, material compatibility, and anisotropic strength. It concludes with a call for further integration of predictive modeling, hybrid material systems, and closed-loop process monitoring to unlock the full potential of additive manufacturing in high-performance engineering applications.