Additively Manufactured Actuators and Their Integration into Real-World Systems

Additive manufacturing (AM) has expanded the design space for actuator systems by enabling complex internal geometries, multimaterial architectures, functional gradients, embedded channels, and application-specific components that are difficult to realize using conventional fabrication alone. These capabilities are particularly relevant when actuator performance is governed by the coupling between material selection, printed architecture, stimulus response, and system-level integration. This review examines additively manufactured actuators and actuator components using a material-architecture-function-integration framework. The actuator classes considered include soft pneumatic and fluidic actuators, electroactive and piezoelectric polymer actuators, shape-memory and 4D-printed actuators, magnetic and magnetoactive actuators, and printed pneumatic, hydraulic, mechanical, and aerospace-grade actuator components. Representative applications are discussed across biomedical and rehabilitation systems, aerospace and deployable mechanisms, soft robotics, and industrial automation. Beyond summarizing printed actuator demonstrations, the review analyzes the integration barriers that determine whether AM actuators can transition from laboratory prototypes to functional systems. These barriers include material durability, leakage, fatigue, dielectric breakdown, filler dispersion, interfacial failure, dimensional variability, environmental sensitivity, auxiliary hardware requirements, sensing, control, and benchmarking. By organizing recent developments across actuator classes, application domains, and integration strategies, this review clarifies where AM provides a functional advantage over conventional fabrication and where further validation is required for reliable deployment.