Advancements in Fused Deposition Modeling: Materials, Processes, and Emerging Trends in Polymer Additive Manufacturing

Fused Deposition Modeling (FDM) has become a leading technology in polymer additive manufacturing due to its versatility, cost effectiveness, and accessibility. This review explores the current advancements, material innovations, and emerging trends within FDM, particularly focusing on high performance polymers and composite materials. Key materials like PEEK (Polyetheretherketone), PEI (Polyetherimide), and PPSU (Polyphenylsulfone) are discussed in terms of their mechanical, thermal, and chemical properties, as well as their applications across industries such as aerospace, automotive, and medical devices. The incorporation of fiber and particle reinforced composites has significantly enhanced FDM capabilities, offering improved strength, rigidity, and thermal resistance for demanding applications. Moreover, the integration of Artificial Intelligence (AI) and the Internet of Things (IoT) is poised to revolutionize the FDM process by enabling predictive maintenance, and real time monitoring. However, challenges such as printability, cost, and material limitations continue to hinder broader adoption, especially for high performance composites and advanced materials. The review concludes by highlighting areas for future research, and material development, which are essential for unlocking the full potential of FDM in both prototyping and end use production.