Additive manufacturing for functional design: a review of capabilities, strategies and applications

Purpose This study aims to recontextualize additive manufacturing (AM) as a platform for functional performance rather than solely geometric innovation. It explores how AM technologies, design strategies and material capabilities converge to enable mechanical, thermal, acoustic, optical and multifunctional applications. Design/methodology/approach The study follows a literature review methodology, examining peer-reviewed articles from top-tier engineering, materials science and multidisciplinary journals. It includes a bibliometric analysis of publication trends and a thematic synthesis of design methods, AM processes and functional outcomes across various domains. Findings The review identifies emerging trends in function-driven AM, including topology optimization with manufacturability constraints, functionally graded materials, architected lattices and hybrid fabrication strategies. It highlights underexplored areas such as acoustic metamaterials, optical functionality and integrated multiphysics systems. The paper also maps specific AM technologies to their functional strengths and limitations. Research limitations/implications While extensive, the review is limited by the availability of English-language publications and may underrepresent emerging work in niche or nonindexed outlets. Future research could further quantify the relationships between process parameters and functional metrics using meta-analytical methods. Practical implications The findings provide a roadmap for researchers and engineers to harness AM technologies in performance-critical sectors such as aerospace, biomedical engineering and energy systems. By aligning AM design strategies with functional goals, the review supports more efficient, sustainable and integrated product development. Originality/value This paper presents a comprehensive, application-focused framework for AM-enabled functional design. It bridges gaps between process parameters, material behavior and end-use performance, offering actionable insights for advancing both academic research and industrial implementation.