Ultrasonic‐Driven and Ultrasonic‐Assisted Additive Manufacturing: Processes, Mechanisms, and Perspective

The integration of ultrasonic energy into additive manufacturing (AM) offers a powerful strategy to overcome persistent challenges in material compatibility and forming quality. This technology is categorized into two approaches: ultrasonic‐driven AM and ultrasonic‐assisted AM. Ultrasonic‐driven AM, a nonmelting solid‐state forming technology, utilizes its unique ultrasonic energy activation mechanism to enable material processing without protective atmospheres or high‐temperature heat sources. As a complementary approach, ultrasonic assistance in AM can effectively reduce porosity and microcracks, refine grain structures, and promote ordered particle alignment in process. Despite these benefits, widespread adoption is hindered by challenges such as complex process control and difficulties in equipment integration. Resolving these bottlenecks is crucial for unlocking the full potential of the technology. Herein, various ultrasonic AM processes are reviewed, with emphasis on advantages and mechanisms. After an overview of the phenomena caused by ultrasonic waves in both solids and fluids, the functions of ultrasonic in AM are introduced. In addition, applications of these processes, such as vivo bioprinting, are briefly introduced. Finally, the trend of ultrasonic AM and perspectives for this new field are highlighted. This summary is intended to provide new ideas for application of ultrasonic in broader AM fields.