Advanced Biodegradable Polymer Materials and Additive Manufacturing

This comprehensive review examines the intersection of biodegradable polymer science and advanced additive manufacturing technologies, synthesizing current knowledge across material development, processing techniques, property enhancement, and applications. The urgent need to address plastic pollution through sustainable alternatives has accelerated research into biodegradable polymers, particularly polylactic acid (PLA) and polyhydroxybutyrate (PHB), which offer promising combinations of mechanical performance and environmental benefits. This article analyzes production methodologies, composite formation strategies, and novel functionalization approaches that enhance mechanical, thermal, and functional properties of these materials. The review explores how additive manufacturing techniques—from material extrusion to vat photopolymerization—have revolutionized the processing of biodegradable polymers, enabling complex geometries and tailored properties unachievable through conventional methods. Advanced manufacturing approaches including field-assisted printing, ultrasonic enhancement, and low-pressure processing are evaluated for their ability to overcome inherent limitations in printed parts. Starting with technologies like 4D printing, the article pays serious attention to the use of shape-memory and stimuli-responsive materials to fabricate dynamic structures that undergo predetermined transformations. The article further explores various applications in the fields of biomedical devices, food packaging, structural components, and consumer goods, discussing both present-day applications and possible future ones. This review covers mechanical performance, biodegradation phenomena, and processing alternatives to provide a broad perspective of the present and future trajectory of biodegradable polymer research to aid researchers, engineers, and industry practitioners aiming toward truly sustainable material solutions.