Application of 3D-printed metal pistons in internal combustion engines: advantages and challenges

The application of 3D-printed metal pistons in internal combustion engines (ICE) presents significant advantages, including enhanced design flexibility, weight reduction, and improved thermal management. This innovative manufacturing technique enables the creation of complex geometries and tailored surface textures, contributing to better fuel efficiency and reduced emissions. Moreover, it opens new possibilities for customised piston design in advanced combustion strategies. However, challenges such as material anisotropy, surface roughness, and long-term reliability must be addressed to ensure consistent and safe performance under demanding engine conditions. Ongoing research in material science, process optimisation, and post-processing techniques is essential for overcoming these hurdles and realising the full industrial potential of 3D-printed pistons in modern ICE technology.