Effect of additives on the FDM 3-D printing: current practice, future prospects, and industrial applications

Purpose This paper intended to systematically review and examine the development and enhancement of polymer-based filaments used in fused deposition modeling (FDM). It also highlights the effects of incorporating nano and micro particles, organic and inorganic additives and fiber reinforcements, as well as the role of bio-based and recycled materials in promoting environmental sustainability. Design/methodology/approach Recent research on composite filament production is analyzed comprehensively to evaluate how various additives and processing parameters influence three-dimensional (3D) print quality, mechanical performance, thermal stability and functional properties. Findings are drawn from multiple industrial sectors, including aerospace, automotive, biomedical and electronics. Findings Fibers, nano/micro-scale additives and recycled materials significantly enhance filament mechanical strength, thermal stability, print accuracy and environmental performance. Advanced filaments reduce material waste, shorten production times and enable more efficient manufacturing of high-performance components. Originality/value This review provides a systematic overview of current strategies in composite filament development, highlighting the effects of different additives and processing parameters and offers insights for future research on high-performance and sustainable 3D printing filaments, bridging material innovation with practical industrial applications.