Advances in Additive Manufacturing for Architectural Acoustics: Design, Materials, Validation, and Implementation Challenges in Building Construction

• Additive manufacturing enables geometry-driven acoustic optimisation through lattice structures, metamaterials, and micro-perforated designs. • A systematic review identifies material type, including cementitious materials, polymers, metals, and earth-based composites, as the primary determinant of sound absorption and insulation performance. • AM technologies (FDM, SLA, SLM) offer distinct capabilities for fabricating tunable acoustic components, with SLA/SLM enabling high-precision resonator and micro-cavity structures. • AI-assisted modelling, topology optimisation, and FEM/BEM simulations enhance prediction and accuracy support performance-driven design workflows. Key limitations include material constraints, structural anisotropy, modeling uncertainties, and the absence of standardized acoustic testing protocols. • NVivo-based content analysis reveals trending themes around acoustic metamaterials, functional grading, simulation-driven design, and sustainable AM feedstocks. The findings establish a framework for integrating additive manufacturing into practical building acoustics by employing multi-scale design, hybrid materials, and validated real world applications. Additive Manufacturing (AM), commonly referred to as 3D printing, has emerged as a transformative technology in the construction sector, enabling unprecedented geometric freedom, automation, and material efficiency. While its adoption for structural applications has accelerated, its integration into building acoustics remains limited and fragmented. This systematic review synthesizes findings from 79 peer-reviewed studies to evaluate the current state of AM for architectural acoustic applications, with emphasis on materials, design strategies, validation methods, and implementation challenges. Four dominant constraint categories are identified: material limitations (≈38%), structural and design constraints (≈19%), modeling and prediction inaccuracies (≈16%), and acoustic performance limitations, particularly narrow operational bandwidths (≈27%). The review highlights the critical role of geometry-driven design, including acoustic metamaterials and micro-perforated panels, enabled by AM processes such as material extrusion, vat photopolymerization, and powder bed fusion. However, persistent challenges related to sustainability, process scalability, surface quality, and limited field-scale validation restrict broader adoption. Emerging solutions, including AI-assisted material formulation, generative acoustic design, and hybrid computational–experimental workflows, are identified as key enablers for progress. The findings provide actionable insights for engineers and designers seeking to deploy AM-based acoustic components in buildings and establish a roadmap for advancing scalable, sustainable, and high-performance architectural acoustics.