A review on the melt extrusion-based fused deposition modeling (FDM): background, materials, process parameters and military applications

Abstract The contemporary military sector needs a tailor-made product at a low cost and time. Fused Deposition Modeling (FDM) is a melt extrusion-based Additive Manufacturing technology for processing thermoplastics, composites, and biomaterials. FDM is competent in fabricating complex parts in different industries, including military, aerospace, automotive, biomedical, and jewellery. The FDM can process various materials and is ideal for fabrication prototypes, functional parts, visualization, concept proofs and fast product development. FDM is currently used in the military for novel components developments and maintenance, opening new logistics and supply chain management methods. Integrating sensors into weaponry for real-time physiological feedback and threat information is also possible. Additionally, FDM can fabricate trauma models for surgical planning and educating military surgeons. This paper presents the FDM background, filaments, and process parameters. Also, the work provides information to readers on the applications and possibilities of the FDM process from a military standpoint.