The growing industrial demand for cost-effective and time-efficient fabrication of complex components in a single setup, particularly for small-batch production, has accelerated the adoption of additive manufacturing (AM). Among various AM techniques, Fused Deposition Modeling (FDM) has emerged as a widely utilized method for manufacturing polymer-based composites with customized properties for diverse applications. The incorporation of reinforcements such as fibers, nanoparticles, and cellulose nanocrystals (CNCs) into thermoplastic matrices, including polylactic acid (PLA), acrylonitrile butadiene styrene (ABS), and polypropylene (PP), significantly enhances the mechanical, thermal, and functional performance of printed components. However, achieving optimal composite properties necessitates precise control over key process parameters, such as extrusion temperature, layer height, printing speed, and infill pattern. This study presents a comprehensive review of recent advancements in FDM printed polymer composites, emphasizing material selection, processing conditions, and their impact on mechanical behavior and critical challenges associated with the printing of polymer composites. The present study highlights the development of high-performance 3D-printed composites, supported by recent advances in additive manufacturing and material science, for potential use in aerospace, automotive and biomedical applications.
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