From Mechanics to Machine Learning in Additive Manufacturing: A Review of Deformation, Fatigue, and Fracture

Additive manufacturing (AM) enables a level of design flexibility that is difficult to achieve with conventional techniques, yet it inherently yields materials marked by significant variability, anisotropy, and sensitivity to defects that challenge classical mechanics-of-materials assumptions. Process-driven microstructural heterogeneity, stochastic defect populations, and residual stresses strongly influence deformation, fatigue, and fracture behavior, often outweighing nominal material properties and constraining the predictive capability of traditional constitutive and fracture mechanics models. Machine learning (ML) has emerged as a powerful means of handling the complexity of AM data; however, many current approaches depend on black-box models that lack physical transparency, extrapolate poorly, and treat uncertainty inadequately. This review contends that ML should augment—rather than replace—mechanics-based modeling, and that dependable prediction of AM material behavior requires mechanics-informed ML frameworks. We critically analyze the central mechanics challenges in AM and evaluate established modeling strategies alongside emerging ML methods relevant to deformation, damage, fatigue, and fracture. Particular emphasis is given to physics-informed and hybrid ML approaches that explicitly incorporate anisotropy, defect sensitivity, residual stress effects, and uncertainty quantification within learning architectures. Recent progress in ML-assisted constitutive modeling, fatigue and fracture prediction, and digital twin development is synthesized, and the implications for qualification, certification, and structural deployment of AM components are discussed.