Light-derived additive manufacturing: advances, challenges and prospects

Light, as a pivotal and versatile energy source, has given rise to a multitude of additive manufacturing (AM) technologies, collectively termed light-derived additive manufacturing (LDAM). This review provides a critical overview of recent advances in four principal categories: Laser Powder Bed Fusion (LPBF), Vat Photopolymerization (VPP), Laser Direct Writing (LDW), and Laser Metal Deposition (LMD). For each technology, we dissect the underlying principles, highlight groundbreaking studies and identify persistent challenges such as defect control in LPBF, material limitations in LMD, and speed-resolution trade-offs in VPP and LDW. The review further offers a unique comparative analysis through technology selection maps, guiding researchers in choosing the appropriate light-based AM process for their specific material and performance requirements. It aims to provide an overview of the current advances of research in this area, identify the still existing challenges and assess the trends and solutions related to specific studies. It expects that this review will prove invaluable reference to researchers and practitioners of AM technology, and that our efforts in this evolving area will contribute to the further advancement of AM.