Recent advances in additive manufacturing of impact-resistant structures with high-performance polymers and their composites

Impact-resistant structures designed to withstand forces and maintain integrity under loads require high compressive strength, energy absorption capacity, tensile strength, and stiffness. These structures typically feature complex geometries that are difficult to produce using traditional manufacturing methods. Additive manufacturing (AM) technology has revolutionized the fabrication of such structures by offering superior capabilities in complexity, customization, and material efficiency. High-performance polymers (HPPs) including polyamide (PA), polyetherimide (PEI), polyphenylene sulfide (PPS), polyaryletherketones (PAEKs), and polyimide (PI) and their composites have gained prominence for impact-resistant applications due to their exceptional mechanical properties and AM compatibility. This review examines recent advances in the AM of HPPs for achieving impact resistance. It focuses on three key areas: the relationship between process parameters and mechanical/energy-absorbing performance, the properties of HPPs and their composites, and the impact-resistant characteristics of novel structural architectures. Additionally, the study addresses the current challenges and future perspectives in developing 3D-printed impact-resistant structures. By synthesizing this information, the review establishes a foundation for future research in innovative AM designs and new material feedstocks for impact-resistant applications.