Recent advances in metal additive manufacturing: Processes,materials,and property enhancements for engineering applications

Abstract

Metal additive manufacturing (MAM) is rapidly transforming the manufacturing industry by enabling the fabrication of complex, lightweight, and high-performance components. While a few researchers have explored individual aspects of MAM, such as processes, materials, and applications, there remains a critical gap in the literature regarding integrated analysis that bridges material behaviors, process optimization, post-processing, and real-world applications. This review addresses that gap by presenting a comprehensive overview of the current state of MAM technologies, evaluating the trade-offs and synergies among various methods such as selective laser melting (SLM) and electron beam melting (EBM), and detailing how mechanical properties can be enhanced through tailored post-processing and material selection. It also discusses the role of simulation, sustainability, and standardization often overlooked in prior reviews. By linking scientific development with industrial implementation, this paper offers a unified perspective to guide future innovations in the engineering application of MAM.