Nanocomposite-based additive manufacturing: Recent advances, applications, challenges, and future prospects

Nanocomposite-enabled additive manufacturing (AM) provides an effective pathway for developing lightweight, multifunctional, and geometrically complex components by integrating nanoscale reinforcements with layer-by-layer fabrication. This review critically evaluates carbon-based, metallic, and ceramic nano-reinforcements used in major AM processes, including selective laser sintering (SLS), fused deposition modeling (FDM), stereolithography (SLA), and direct ink writing (DIW). The analysis focuses on structure–property relationships, nanoparticle dispersion, interfacial interactions, process compatibility, performance trade-offs, scalability, sustainability, and application potential. Studies indicate that nanofillers can enhance mechanical, electrical, thermal, antimicrobial, and biological properties; however, these improvements depend strongly on matrix composition, filler concentration, dispersion quality, processing conditions, printing parameters, build orientation, and post-processing methods. Therefore, reported enhancements from specific material–process combinations cannot be universally applied across different AM platforms. Despite significant progress, challenges such as nanoparticle agglomeration, weak interfacial bonding, limited reproducibility, high costs, environmental and occupational safety concerns, and the absence of standardized evaluation methods continue to restrict industrial implementation. Future developments will require improved surface functionalization, real-time process monitoring, data-driven optimization, hybrid feedstocks, recyclable materials, and reliable testing standards. By integrating findings across different nanomaterial classes and AM technologies, this review identifies current advances, conflicting evidence, and critical research gaps toward the development of robust and scalable nanocomposite-based AM systems.