Development of Wear-Resistant Polymeric Materials Using Fused Deposition Modelling (FDM) Technologies: A Review

The advancement of 3D printing technology has changed material design and fabrication across various industries. Among its many applications, the development of high-wear-resistance polymer composites, particularly using Fused Deposition Modelling (FDM), has received increasing interest from both academic and industrial sectors. This paper provides an overview of recent advances in this field, focusing on the selection of key printing parameters (such as layer thickness, print speed, infill density, and printing temperature) and material compatibility optimisation to enhance print quality and tribological performance. The effects of various tribo-fillers, such as fibres and nanoparticles, on the tribological properties of the printed polymer composites were studied. Generally, in the case of nano-sized particles, the wear rate can be reduced by approximately 3 to 5 times when the nanoparticle content is below 5 vol.%. However, when the nanoparticle concentration exceeds 10 vol.%, wear resistance may deteriorate due to the formation of agglomerates, which disrupts the uniform dispersion of reinforcements and weakens the composite structure. Similarly, in short fibre-reinforced polymer composites, a fibre content of 10–30 vol.% has been observed to result in a 3 to 10 times reduction in wear rate. Special attention is given to the synergistic effects of combining micro- and nano-sized fillers. These advancements introduce novel strategies for designing wear-resistant polymer composites without requiring filament fabrication, making 3D printing more accessible for tribological applications. In the last part of the review, the impact of emerging AI technologies on the field is also reviewed and discussed. By identifying key research gaps and future directions, this review aims to drive further innovation in the development of durable, high-performance materials for wide industry applications in aerospace, biomedical, and industrial engineering.