Bioinspired Design in Additive Manufacturing: A Review of AI, Multi-Scale Strategies, and Fabrication Constraints

Bioinspired design represents a paradigm shift in engineering, drawing upon millions of years of evolutionary optimization to create advanced structures and materials. This comprehensive review examines the intersection of bioinspired design principles with additive manufacturing (AM) technologies, focusing on multi-scale strategies and the inclusion of artificial intelligence (AI) to create lightweight, efficient, and multifunctional components. We analyse key biological design principles, including hierarchical organization, lightweight efficiency, and multifunctionality, demonstrating how these can be translated into engineering solutions through AM. The review covers state-of-the-art design strategies, including lattice structures, topology optimization, generative design, and multi-scale modelling approaches, with a particular focus on the constraints imposed by fabrication processes. We examine digital tools that facilitate the translation of biological models into manufacturable designs, including computer-aided design systems and AI platforms. Current challenges in scaling, first-time-right fabrication, and complexity management are critically assessed, along with knowledge gaps in structure-property-process relationships. The outlook section presents future directions for industrial integration, emphasizing the potential for bioinspired AM to revolutionize multiple sectors, from aerospace to biomedical applications