Manufacturing of polymer-based composite material by FDM: challenges and opportunities for functional parts design

Additive manufacturing has opened a new chapter in manufacturing, particularly Fused Deposition Modeling (FDM), which has emerged as a low-cost, flexible technology for producing complex polymer parts. This study aims to highlight real-world applications of polymer composite materials produced via FDM and to provide a thorough analytical and critical assessment of the fundamental challenges that currently limit FDM adoption for functional end-use parts across a wide range of applications. The primary focus is on the causal relationships between process parameters and material performance. Key limitations, such as interlayer adhesion and void formation, are analyzed through the lens of polymer physics and heat transfer, introducing concepts like molecular diffusion. Furthermore, the paper offers a strategic framework for future research, highlighting critical areas such as Functionally Graded Additive Manufacturing (FGAM), intelligent topology optimization, and 4D Printing. This review identifies knowledge gaps and delineates a clear pathway to transform Fused Deposition Modeling (FDM) into a resilient, industrially feasible manufacturing process suitable for high-performance composite components.