Additive Manufacturing Using Multi-Materials: Materials, Processes, and Applications

Additive manufacturing (AM) has transformed traditional manufacturing by enabling the fabrication of complex geometries and functional components that are difficult or impossible to produce using conventional techniques. Recent advancements have expanded AM capabilities through the integration of multi-material systems, allowing for enhanced performance, customisation, and functionality of manufactured parts. Despite rapid development, there is a limited consolidated understanding of the processes, material combinations, and practical implications of multi-material additive manufacturing (MMAM) across different application domains. This study aims to provide a comprehensive overview of general additive manufacturing processes, with a particular focus on the evolution and implementation of multi-material fabrication techniques. The review draws upon publicly available scientific literature to analyse various AM technologies, material pairing strategies, and process parameters. Comparative analysis is conducted between the additive and conventional manufacturing approaches to highlight advantages and limitations. The findings reveal significant progress in material compatibility, interface bonding, and process integration, enabling the production of multifunctional and performance-optimised components. Diverse applications are identified across aerospace, biomedical, and industrial sectors. MMAM represents a critical advancement in modern manufacturing, offering expanded design freedom and functional integration. Continued research is essential to address the remaining challenges in material compatibility, scalability, and process standardisation.