Recent trends on additive manufactured advanced materials: a targeted review on functional capabilities and process integration

Abstract Additive manufacturing (AM) has transformed traditional manufacturing processes, revolutionizing the production of complex, customized, and high-performance components. The role of advanced materials developed specifically for AM technologies is critical to the success of this transformation. This review comprehensively covers advanced material classes such as metal-based alloys, ceramics, high-performance polymers, composite systems, smart materials, and functionally gradient materials (FGMs). The compatibility of each material group with AM processes, its mechanical and functional properties, post-production requirements, and application potential are detailed. Furthermore, the compatibility between material selection processes and manufacturing technologies is comparatively evaluated in terms of application-specific performance outcomes. Supported by recent case studies selected from the literature, this review discusses prominent applications, particularly in the aerospace, biomedical, and automotive sectors. Current challenges such as microstructural control, post-process optimization, environmental sustainability, and multi-material manufacturing are also addressed, and future research areas such as AI-assisted material design and nano-additive systems are highlighted. As a result, the integration of advanced material development and AM processes stands out as the key determinant in the production of functional, durable and sustainable products.