Fabrication Methodologies of Functionally Graded Materials: Advances, Performance Regulation, and Future Perspectives

ABSTRACT Functionally graded materials (FGMs) exhibit outstanding strength, thermal resistance, and compatibility with biological systems, which makes them valuable in fields such as aerospace, automotive, and biomedical engineering. However, conventional fabrication methods face inherent limitations due to process‐specific constraints, which restrict the efficient production of complex structures and tailored properties required in modern industries. Advances in manufacturing techniques have demonstrated great potential for improving the performance of FGMs. This review highlights five primary fabrication routes: gas‐based, liquid‐based, solid‐based, additive manufacturing, and severe plastic deformation, along with their influence on material properties. Among these methods, techniques like laser‐based deposition and powder‐bed fusion in additive manufacturing have shown considerable promise in modern production approaches. The integration of different processing routes has further demonstrated substantial improvements in the structural and functional properties of FGMs. Moreover, the incorporation of advanced simulation tools and artificial intelligence algorithms for process optimization is expected to greatly improve both manufacturing efficiency and material performance. Finally, this review highlights the current challenges in FGM fabrication and outlines future directions for multi‐scale, interdisciplinary development, which are anticipated to accelerate their industrial application.