Integrating additive manufacturing with biodegradable polymers for sustainable biomedical engineering: a state-of-the-art review

The rapid expansion of plastic consumption has intensified environmental contamination and microplastic accumulation in ecosystems and food chains, while biodegradable polymers combined with additive manufacturing (AM) provide sustainable biomedical alternatives. This systematic review applied PRISMA 2020 guidelines and a PICO-based framework to analyze 162 studies published between 2015 and 2025 on several biodegradable polymers for biomedical AM applications. Degradation behavior varied from several weeks to months depending on polymer composition, fabrication route, and application. Composite and hybrid formulations improved mechanical strength by 30–60% compared with single-polymer systems. Life-cycle assessments demonstrated global warming potential reductions of nearly 50–80% relative to petroleum-derived plastics, although disposal strategies and regional energy sources strongly influenced outcomes. Biopolymers additionally reduced energy consumption by 65% and greenhouse gas emissions by 35–80%. Nanoclay-reinforced PLA exhibited 45% lower climate-change impact than LDPE and 39% lower than PP. PCL reached 87% degradation within 18 weeks, whereas PLA/PHB (50:50) blends achieved 85% degradation after 50 days under composting conditions. FDM remained the dominant AM technique, while SLA and SLS enabled higher precision despite economic and material constraints. Future priorities include regulatory harmonization, AI-guided material optimization, circular recycling strategies, scalable biomaterials, and clinically validated manufacturing processes for sustainable healthcare worldwide biomedical applications.