Innovative polymer‐based composite materials in additive manufacturing: A review of methods, materials, and applications

Abstract This review paper delves into the manufacturing methods, material properties, and applications of polymer‐based composites in the field of advanced manufacturing, offering a detailed explanation of their production through various additive manufacturing (AM) techniques and their diverse applications across multiple industries. Polymer‐based composite materials have emerged as crucial elements in AM due to their enhanced properties and design versatility, enabling the creation of components with unprecedented performance characteristics. The paper comprehensively covers the major AM methods employed for composite materials, including fused filament fabrication, Digital Light Processing/Stereolithography, Direct Ink Writing, and Selective Laser Sintering. Each of these methods is explored in terms of its mechanism, suitability for different composite materials, and the resulting material properties. The review also provides an insightful analysis of how these AM techniques are revolutionizing industries such as soft robotics, mechanical, electrical, and biomedical fields. The paper concludes by discussing the current challenges in this domain and projecting future trends in the development and application of composite materials in advanced manufacturing. This review aims to offer a comprehensive resource for researchers and practitioners in the field, highlighting the transformative impact of polymer‐based composites in AM and their growing significance across various sectors. Highlights Comprehensive review and classification of novelties in printing method for polymer based composite material manufacturing. Introduces innovative techniques to create and enhance material properties of composites. Explores interdisciplinary applications in biomedical, electronics, and sensors, demonstrating material versatility. Provides a systematic correlation between manufacturing method, material properties, and applications of novel polymer‐based composites.