Bioinspired design, inspired by nature’s time-tested principles, has become a transformative approach in engineering and allows the development of innovative solutions by mimicking the efficient structures and mechanisms found in biological systems. Integrating with additive manufacturing (AM), bioinspired design facilitates the creation of complex, multi-material, and multifunctional structures that offer superior performance compared to traditional manufacturing methods. This review delves into the synergies between bioinspired design and AM, emphasizing how natural concepts, such as Bouligand-like structures, nacre-inspired composites, hierarchical architectures etc., are utilized to enhance material properties like toughness, fracture resistance, and energy dissipation which is crucial to the field of 3D printing. These advancements have led to breakthroughs in aerospace, biomedical engineering, and environmental technologies, including lightweight and impact-resistant components, tissue scaffolds for regenerative medicine, self-cleaning surfaces, and anti-fouling coatings. The paper also identifies key material considerations for successful bioinspired AM, focusing on polymers, composites, hybrid materials, and nanomaterials essential for realizing these innovations. Despite the immense potential, challenges remain in replicating the multifunctionality and scalability of natural systems, especially in terms of digital modeling, multi-material printing techniques, and cost-efficiency. Looking forward, the combination of bioinspired design with advancements in generative design, artificial intelligence, and novel materials will pave the way for future innovations, offering sustainable and high-performance solutions across diverse industrial applications. This review ultimately demonstrates how the fusion of nature-inspired design principles with AM technologies can unlock innovative solutions to modern engineering challenges.
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