Mass Customisation Strategies in Additive Manufacturing: A Systematic Review and Implementation Framework

Additive manufacturing (AM) has transformed mass customisation by allowing personalised production with remarkable efficiency. This systematic review compiles findings from 61 peer-reviewed articles (2010–2024) to highlight strategies for implementation, technological facilitators, challenges, industry applications, and evaluation frameworks relevant to mass customisation in AM contexts. Utilising the Preferred Reporting Items for Systematic Reviews and Meta-Analyses (PRISMA) methodology, the review applies stringent inclusion criteria and thematic analysis to create an in-depth understanding of this developing area. Four major strategies for implementation have been identified: combining AM with conventional manufacturing, integrating customer-centred design, establishing flexible manufacturing networks, and creating adaptive production systems. Key technological facilitators include capabilities for multi-material processing, integration of digital workflows, and advanced monitoring of processes, while obstacles consist of limitations in materials, challenges in quality assurance, and complexities related to digital asset management. Industry applications reveal tailored approaches specific to medical, industrial, and architectural sectors. This analysis presents a multi-tiered implementation framework encompassing strategic, tactical, operational aspects and performance evaluation aspects to assist organisations in embracing AM-based mass customisation. This framework fills a notable gap in existing literature by aligning personalisation goals with operational efficiency. This paper also outlines future research priorities, such as creating standardised evaluation methods, improving system reliability, incorporating sustainability, and leveraging emerging tools like AI for process improvement. Ultimately, this review bridges theory and practice, offering a clearer path forward for mass customisation in the era of AM.