Review of polymer fused deposition material additive manufacturing technology for aerospace application

This review article explores the polymer-based fused deposition modeling (FDM) role in aerospace additive manufacturing. It focuses on analyzing thermoplastics like ABS, PEEK, and PEI. Composites such as carbon fiber-reinforced PEEK are also examined. The research uses scientific literature and industrial examples. Real cases highlight FDM’s ability to create lightweight, complex designs. The technology also reduces material waste and costs. Semi-crystalline polymers like PEEK show high strength-to-weight ratios. Their oriented molecular chains improve performance. Amorphous polymers, such as ABS, are cheaper but less thermally stable. Composites bridge the gap between polymers and metals. Carbon fiber-reinforced PEEK offers tensile strengths up to 100 MPa and withstands temperatures above 260°C without adding density. The study links polymer microstructure to function. Crystalline regions enhance strength. Amorphous areas limit thermal resistance. Ashby plots compare tensile strength, density, and cost. These charts guide material selection. Practical insights include guidelines for material selection. ABS suits prototypes and non-critical parts like UAV brackets. PEEK and PEI are better for high-stress uses, such as outer panels. Printed parts often have directional weakness (anisotropy). Long-term durability data under extreme conditions is scarce. Examples include UV exposure and cyclic loading. Performance varies across FDM printers. Standardization and certification remain challenges for critical systems. Future work should focus on high-temperature polymers for hypersonic flight. Multi-material printing could create graded parts, like heat-resistant exteriors with flexible interiors. Bio-sourced or recyclable filaments would support sustainability. AI-driven optimization may improve defect detection. Hybrid methods, like combining FDM with CNC machining, could boost precision. The research provides a roadmap to address technical and regulatory barriers. It positions FDM as a sustainable solution for aerospace. Balancing performance, cost, and environmental goals is key.