Additive Manufacturing Technology and Its Application Research

Juncheng Yu

School of Mechanical and Aerospace Engineering, Nanyang Technological University, 50 Nanyang Avenue, Singapore

Keywords: Additive Manufacturing, 3D Printing, Technology Application, Development Trends, Biomedical, Aerospace.

Abstract: Additive Manufacturing (AM) technology has revolutionized traditional manufacturing processes through an

innovative method of layer-by-layer material stacking, widely applied in aerospace, biomedical,

transportation, and other fields. This paper systematically reviews seven mainstream additive manufacturing

processes under international standards, including photopolymerization, powder bed fusion, material

extrusion, and analyzes their technical advantages through typical application cases, introducing the latest

application progress of additive manufacturing in popular fields. However, additive manufacturing still faces

multidimensional constraints such as materials, process technology, and social environment. In the future, it

is necessary to promote its development towards standardization, greening, and scaling to unleash its

technological potential.

1 INTRODUCTION

Additive Manufacturing (AM) technology is an

emerging technology for manufacturing physical

parts, fundamentally realized through layer-by-layer

material stacking to construct three-dimensional

entities, overturning the traditional subtractive

processing methods and the logic of "subtracting"

materials. Its core principles include digital design,

slicing, layer-by-layer forming, and post-processing,

particularly suitable for complex geometric structures,

lightweight design, and personalized customization

scenarios. In the past decade, AM technology has

developed rapidly, continuously expanding its

technical boundaries, achieving a leap from the initial

single-material static forming artifacts to producing

precision components across multiple fields

including construction, transportation, aerospace, and

biomedical, demonstrating strong process

compatibility and applicability in various scenarios,

as well as broad future application prospects.

This paper will focus on AM processes,

summarizing the latest developments in AM across

several different industry sectors in recent years and

the current challenges faced, while also looking ahead

to the development trends in the coming years.

https://orcid.org/0009-0000-3398-8930

2 OVERVIEW OF ADDITIVE

MANUFACTURING

PROCESSES

Additive manufacturing (AM), commonly referred to

as 3D, is a technology that constructs three-

dimensional entities by continuously forming layers

of material in a manner similar to the operation of

conventional printer nozzles, under predetermined

program control. It has demonstrated unique value

across various fields due to its ability to overcome the

limitations of subtractive and formative

manufacturing processes. In terms of application, the

aerospace sector has widely adopted AM technology

to produce lightweight complex components, such as

the fuel nozzle of the LEAP engine produced by

General Electric (GE) through metal 3D printing

technology, which not only integrates 20 traditional

parts into a single component but also achieves a 25%

weight reduction and enhanced durability. In the

medical field, this technology supports personalized

medicine by customizing orthopedic implants, dental

restorations, and surgical guides based on patient CT

data, and in recent years, it has extended into the field

of bioprinting, exploring the possibilities of

constructing living tissues and organs, as seen in the

research conducted by Professors Dai Kerong and

232

Yu, J.

Additive Manufacturing Technology and Its Application Research.

DOI: 10.5220/0014350000004718

Paper published under CC license (CC BY-NC-ND 4.0)

In Proceedings of the 2nd International Conference on Engineering Management, Information Technology and Intelligence (EMITI 2025), pages 232-238

ISBN: 978-989-758-792-4

Hao Yongqiang from Shanghai Jiao Tong University

on the application of AM in orthopedic clinics. The

automotive industry utilizes its rapid prototyping

characteristics to accelerate product development

cycles while producing lightweight chassis

components and customized interior parts.

Meanwhile, the construction industry is attempting to

use concrete 3D printing technology to achieve

unconventional architectural structures and low-cost

rapid construction(Liu, 2025, Wang, 2025).

In terms of classification systems, in 2010, the

International Organization for Standardization (ISO)

and the American Society for Testing and Materials

(ASTM) established the ISO/ASTM 52900 standard,

which defines seven mainstream processes. These

include photopolymerization technology, powder bed

fusion technology, material extrusion technology,

binder jetting technology, material jetting technology,

directed energy deposition technology, and sheet

lamination technology(Wu, Zhou and Shi et al. 2024).

2.1 Photopolymerization Technology

The basic principle of photopolymerization

technology is to manufacture three-dimensional

objects by utilizing the rapid curing characteristics of

liquid photosensitive resin under specific

wavelengths and intensities of light. Currently, the

more mainstream photopolymerization technologies

include SLA, DLP, DPP, and CLIP.

SLA is one of the earliest rapid prototyping

technologies, invented by American engineer Chuck

Hull in 1986. It works by controlling a laser beam to

scan the surface of liquid photosensitive resin, curing

each layer’s cross-section point by point, and stacking

layers to form a solid object. SLA technology offers

high precision, capable of achieving ±0.1 mm or even

higher dimensional accuracy, with good surface

quality that facilitates subsequent fine processing and

painting.

DLP technology utilizes Digital Micromirror

Devices (DMD) to modulate UV light sources into

specific patterns, curing a layer of resin in a single

exposure. Its advantages include high speed, making

it particularly suitable for producing complex and

intricate small components, such as medical, dental

models and jewelry.

DPP technology uses liquid crystal displays

instead of conventional lasers to cure polymers.

Therefore, the polymer resins used also require

special formulations for production. Currently, the

most sensitive resins for DPP are produced by the UK

company Photocentric.

CLIP is a continuous liquid interface printing

method developed by a team led by Professor

DeSimone at the University of North Carolina. The

printing method is similar to DLP. Its core principle

is to create a "dead zone" beneath the ultraviolet

image projection plane using an oxygen-permeable

window to suppress the photopolymerization reaction,

enabling continuous production. This allows complex

solid parts to be pulled from the resin at speeds of

hundreds of millimeters per hour, significantly

increasing printing speed. Additionally, this

technology features high surface quality, good

mechanical properties, and advanced resin printing

techniques, allowing for better control of surface

roughness.

Overall, photopolymerization technology is more

suitable for biomedical and fine object production

(Bao, 2024), while it is limited by modeling size and

material strength, making it unsuitable for the

production of industrial mechanical parts.

2.2 Powder Bed Fusion Technology

Powder bed fusion technology manufactures parts by

selectively melting metal or plastic powders in a

powder bed using thermal energy. It is mainly divided

into SLM, EBM, and DMLS.

SLM technology uses high-energy laser beams to

melt metal powders and rapidly solidify them,

achieving the manufacture of fully dense metal parts.

Therefore, the finished parts produced have complex

shapes, high precision, and excellent mechanical

properties. However, challenges such as high

equipment costs and complex process parameter

control are also troubling researchers engaged in this

technology. The early research and development of

SLM technology received strong support from the

German government, and the Fraunhofer Institute for

Laser Technology summarized years of laser melting

experience, combining all known patents related to

SLM to design the first commercial machine.

EBM technology was invented by Arcam, with its

founder Dr. Magnus Resch and others innovating on

the basis of EBM technology, making it suitable for

the field of AM. Its principle is to use the thermal

effect of the electron beam to melt metal powder in a

vacuum environment, making it suitable for

manufacturing high-strength, complex metal parts.

DMLS was developed by companies like EOS

based on early laser sintering technology. Its principle

is that DMLS technology melts and bonds metal

powder through laser sintering, forming parts.

Powder bed fusion technology is widely used in

industrial and biomedical fields. In the aerospace

Additive Manufacturing Technology and Its Application Research

233

sector, SLM technology is used to manufacture

complex components such as aircraft engine blades

and fuel nozzles. The aircraft landing gear

components manufactured by Airbus using SLM

technology effectively reduce weight and improve

fuel efficiency. EBM technology has made progress

in the biomedical field, such as in the production of

artificial joints and dental implants, with parts

exhibiting good biocompatibility and mechanical

properties. DMLS technology is widely applied in the

automotive manufacturing industry for producing

engine blocks, transmission components, etc.,

enabling lightweight design and performance

optimization of complex structures (Liu, 2023, Yao,

2022).

2.3 Material Extrusion Technology

Material extrusion technology is a technique that

extrudes filamentous thermoplastic materials (such as

PLA, ABS, nylon, etc.) through a heated nozzle and

builds up layers according to a predetermined path. It

is mainly divided into FDM and FFF.

FDM (Fused Deposition Modeling) is one of the

earliest material extrusion technologies. In 1988, the

founder of Stratasys proposed the concept of FDM

technology, patented it in 1989, and commercialized

it in 2000, promoting its widespread application. The

principle of FDM technology is to heat filamentous

material to a molten state and then extrude and

solidify it layer by layer along a preset path. The

production process has advantages such as low

equipment costs, ease of operation, a wide variety of

materials, and no need for complex support structures,

but the product precision and surface quality are

relatively low, the forming speed is slow, and there

may be issues such as warping and deformation in

printing large, complex structures.

FFF (Freeform Fabrication) technology is similar

to FDM but emphasizes its open-source and low-cost

characteristics. Open-source projects like RepRap

have played an important role in promoting the

development of this technology.

As the AM technology that most closely aligns

with people’s impression of the concept of "3D

printing," material extrusion technology is favored by

universities and research institutions. Students and

teachers can use it to quickly create models and

prototypes, assisting in teaching and research. In

maker spaces and small studios, this technology is

also popular, being used for the design and production

of creative products. In recent years, with continuous

advancements in materials and equipment, the

application of FDM/FFF technology in the industrial

sector has gradually increased. For example, in the

rapid manufacturing of automotive components,

some car manufacturers utilize this technology to

produce non-critical parts such as interior

components and fixtures, shortening the product

development cycle and costs. In the field of

personalized custom products, such as customized

headphone shells and phone cases, this technology

can quickly manufacture unique DIY products based

on specific user needs (Li, Zhang and Wang et

al,2023, Ge,2024).

2.4 Binder Jetting Technology

In 1993, Professors Emanuel Sachs and Michael

Cima from the Massachusetts Institute of Technology

(MIT) applied for a patent for binder jetting

technology. The principle involves the layer-by-layer

bonding of powder materials (such as metal powder,

ceramic powder, sand, etc.) through the injection of a

binder. During the printing process, a layer of powder

material is first spread, and then the nozzle sprays the

binder along a predetermined path, bonding the

powder together to form a cross-section of the part.

This process is repeated layer by layer until the part

is fully formed. This technology can achieve

relatively large forming sizes and has a faster forming

speed, allowing for a certain degree of parallel

manufacturing. The raw materials for this technology

can include various powder materials, such as metals,

ceramics, and sand, providing great flexibility in

material selection. However, due to the limited

bonding strength of the binder, the parts produced

usually require post-processing, such as sintering or

infiltration, to enhance their strength and density,

making the process quite cumbersome. Additionally,

compared to other technologies like extrusion

molding, this technology tends to produce a looser

structure, which can lead to low-density issues when

directly producing metal or ceramic material products.

ExOne Company plays a crucial role in the

commercialization of this technology. The company

has successively launched various models of 3D

printing systems, such as the S-Print. Compared to the

very expensive conventional metal 3D printers,

ExOne’s binder jetting technology printing

equipment is much more affordable.

The binder jetting technology is currently widely

used in the construction field for manufacturing large

building components, such as walls and decorative

parts. At the same time, in the industrial metal

manufacturing sector, this technology is used to

produce products with complex shapes, such as

automotive engine parts and aerospace components.

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By spraying metal powder and binder, followed by

sintering and other post-processing, metal parts with

complex internal structures and good performance

can be obtained.

2.5 Material Jetting Technology

Material jetting technology involves spraying liquid

or semi-solid materials (such as photosensitive resins,

metal wax, thermosensitive wax, etc.) in the form of

tiny droplets onto a build platform through a nozzle,

layer by layer, according to a preset path. It is similar

to traditional inkjet printing technology, but the

materials being jetted have curable or adhesive

properties, allowing them to solidify or bond into

solid layers after being sprayed. Therefore, material

jetting technology has extremely high precision and

surface quality, capable of producing complex parts

with smooth surfaces and rich details. Additionally, it

can achieve simultaneous jetting of multiple materials,

thereby creating multi-material parts with different

properties and colors.

However, due to the tendency of the nozzle to clog

and the strict requirements for material viscosity,

surface tension, and other conditions, along with

relatively slow printing speeds, this technology is

difficult to apply in the production of large parts.

Thus, material jetting technology is often used to

create high-precision jewelry models or intricate

medical models. In the industrial field, this

technology is primarily limited to the product

development and design verification stages, where

designers use it to quickly manufacture scaled-down

prototypes that closely resemble the final product in

appearance and function for functional testing and

appearance evaluation.

2.6 Directed Energy Deposition

Technology

Directed energy deposition technology is an AM

technique that delivers materials such as metal

powder or wire to a specific location through a nozzle,

while simultaneously using energy sources like lasers,

electron beams, or plasma arcs to melt the material

and build it up layer by layer. Its notable feature is its

high deposition efficiency, allowing for the

manufacture of large parts in a relatively short time,

with potential for large-scale industrial production.

Furthermore, this technology is also suitable for

repairing and adding to existing parts, achieving

localized material addition and performance

optimization, thus having good application prospects

in maintenance and coating projects.

However, directed energy deposition technology

has high requirements for equipment and operating

environments, necessitating precise control of the

energy source parameters and material delivery speed

to ensure the quality and performance of the parts.

Additionally, the manufactured parts may have

certain internal stresses and deformations, requiring

appropriate post-processing.

In the aerospace field, directed energy deposition

technology has achieved significant application

results. The team of Wang Fude and Zhou Qingjun

from Capital Aerospace Machinery Co., Ltd.

elaborated on the manufacturing difficulties, research,

and application progress of three typical structures in

aerospace equipment: the main load-bearing structure,

the integrated structure of heterogeneous alloys, and

the integrated flow channel structure. Some aircraft

manufacturers have adopted this technology to

produce large aircraft structural components, such as

wing beams and fuselage frames. By melting metal

powder with a laser and stacking it layer by layer, it

is possible to achieve lightweight design and the

manufacturing of complex structures while ensuring

the performance of the parts. In the field of metal part

repair, this technology is widely used to repair high-

value metal components, such as automotive engine

crankshafts and gas turbine blades. By adding the

same or different metal materials to the damaged

areas and performing melting deposition, the

dimensions and performance of the parts can be

restored, extending their service lif7.

2.7 Sheet Lamination Technology

Sheet lamination technology, also known as

Laminated Object Manufacturing (LOM), was

successfully developed by engineer Michael Feygin

from HeIisys in the United States in 1986. Currently,

Nanjing Zijin Zhude Electronics Co., Ltd. in China

has become the only company in the world to hold the

core patent for this technology, having launched a

related commercial 3D printer in 2010. As a result,

laminated object manufacturing has become the only

key technology among many rapid prototyping

techniques mastered by a Chinese enterprise. Its

principle is to use sheet materials (such as paper,

plastic sheets, metal foils, etc.) to layer and form

through processes like bonding and cutting, thus

offering advantages of low cost and a wide selection

of materials. Sheet lamination technology can

produce parts with certain strength and dimensional

accuracy, and during the cutting process, it can

simultaneously cut out internal support structures,

facilitating the manufacturing of complex shapes.

Additive Manufacturing Technology and Its Application Research

235

However, the interlayer bonding strength of the parts

is relatively low, and the surface quality is poor,

requiring certain post-processing, such as sanding and

painting, and the thickness of the materials somewhat

limits the precision and detail representation of the

parts(Yu,2011).

In the field of cultural and creative product

manufacturing, sheet lamination technology is used to

create models, sculptures, decorations, and more. For

example, using LOM technology to laminate

materials like paper into shapes, creating works with

unique textures and artistic effects. During the

product design validation phase, this technology is

used for rapid manufacturing of product appearance

models and functional models, helping designers

achieve design visualization, shape evaluation, and

assembly inspection. Some consumer electronics

manufacturers use LOM technology to create shell

models for products, conducting appearance design

and ergonomic testing.

3 LATEST RESEARCH AND

APPLICATIONS

3.1 Biomedical Field

In recent years, in the biomedical field, AM

technology is advancing from external printing to in-

situ manufacturing, pushing personalized medicine

into a non-invasive era. The imaging-guided deep

tissue in vivo ultrasound printing (DISP) technology

developed by the California Institute of Technology

is a revolutionary breakthrough(Elham,2025). This

technology combines focused ultrasound with

specially designed "ultrasound ink," delivering ink

containing biopolymers and thermosensitive

liposomes to target areas in the body via injection or

catheter, using ultrasound transducers to trigger a

localized mild heating gelation reaction, achieving

non-invasive in-situ printing. In experiments, the

team successfully printed drug-loaded biomaterials

near bladder tumors in mice and in deep muscle

tissues of rabbits, validating its potential in drug

release and tissue repair. The high-precision real-time

monitoring and ink adjustability (such as conductivity

enhancement and tissue adhesion) of the DISP system

provide possibilities for in vivo construction of

complex structures like cardiac stents and nerve

conduits, and safety assessments show excellent

biocompatibility with no significant inflammatory

response.

Traditional 3D bioprinting has achieved

customized bone and cardiac stents ex vivo, but still

requires surgical implantation, while DISP

technology completely bypasses this step. Combined

with artificial intelligence path planning, it is

expected to directly print functional tissues or

electronic devices in the future, such as precisely

depositing drug-loaded gels at tumor sites for targeted

therapy, or constructing conductive scaffolds around

damaged nerves to promote regeneration.

Additionally, innovations by Hunan Huashu High-

Tech in improving equipment efficiency also

indirectly support medical applications; their "multi-

laser overlap verification device" significantly

shortens equipment preparation time through water-

cooled flow channels and aluminum plate design,

providing technical support for the rapid production

of high-precision medical implants. These

breakthroughs not only reduce treatment trauma and

risks but also, through the collaborative innovation of

materials and processes, open up unprecedented

possibilities for regenerative medicine and precision

healthcare(Fu and Wang, 2024).

3.2 Aerospace and Transportation

Industry

AM technology has achieved several groundbreaking

advancements in the aerospace and industrial sectors.

Qingdao Saifei Equipment Co., Ltd. has significantly

improved manufacturing efficiency, material

performance, and the ability to realize complex

structures by introducing electron beam liquid phase

forging technology. This technology uses a cold

cathode electron beam gun to rapidly bombard metal

wire materials, utilizing kinetic energy to shape the

material, which not only increases the density of parts

to 100% but also ensures that the proportion of

equiaxed grains exceeds 90%, with mechanical

properties reaching or even surpassing traditional

forging levels. Internationally, this technology has

been successfully applied in the manufacturing of

core components for SpaceX rocket engines (such as

C103 tungsten alloy propulsion system components)

and Airbus aerospace structural parts, providing a

new solution for the production of complex structures

like aerospace-grade pressure vessels and aircraft

engine components due to its low loss (material loss

is only 10%) and high efficiency characteristics.

Domestically in China, the China Academy of

Launch Vehicle Technology, in collaboration with

Capital Aerospace Machinery Co., Ltd., has

developed intelligent path planning and stress control

technology to address the efficiency and precision

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challenges of 3D printing large components. This

technology has successfully improved the surface

precision of stainless steel components to the

millimeter level and has avoided the use of traditional

support structures through an intelligent platform,

significantly reducing processing costs by 60%. This

achievement has been applied to the new generation

of aerospace equipment and has won the Special Prize

for Innovation from the China Association for

Technology in 2024. In terms of university teams,

Professor Wei Zhengying’s team has proposed a

droplet + arc AM method (DAAM) to address

oxidation and heat input issues in aluminum alloy

AM (He,Wei and Wang et al,2023), achieving

efficient deposition of 2219 aluminum alloy thin-

walled parts (with a rate of 140mm3/s ), where the

tensile strength in the horizontal direction reaches

435MPa and the elongation in the vertical direction

reaches 16.4%, providing a new path for the

manufacturing of lightweight structures in rail transit

and spacecraft. Professor Wang Xiaojun’s team from

Harbin Institute of Technology has optimized the heat

treatment process in the laser powder bed fusion

(LPBF) process of nickel-based superalloy

(IN718)(Ding, Miao and Chao et al,2025),

significantly enhancing the strength-plasticity

balance through process simplification, with tensile

properties surpassing traditional forging levels,

offering a better solution for the manufacturing of

high-temperature components such as gas turbines.

4 CONCLUSION

Although AM shows revolutionary potential in

multiple fields, its future development still faces a

series of systemic challenges. From the perspective of

the technology itself, particularly in terms of

materials science, for instance, in the AM of metal

materials, despite the application of high-

performance materials such as titanium alloys and

nickel-based superalloys advancing aerospace and

medical implant manufacturing to new heights, the

performance bottlenecks of materials under extreme

conditions remain significant. The three major pain

points exposed by Toyota in automotive AM—long

material certification cycles, insufficient resistance to

cyclic loading (engine components need to withstand

over ten million vibrations), and poor dimensional

stability under high-temperature conditions—are a

microcosm of the limitations of material systems.

Analyzing from the perspective of process

optimization and equipment innovation, taking

directed energy deposition technology suitable for

large-scale production as an example, although

breakthroughs have been made in the repair of large

aerospace components and the integrated

manufacturing of heterogeneous alloys, the risk of

uncontrolled dynamic behavior of the melt pool in

microgravity environments (such as melt pool shape

distortion caused by the absence of thermal

convection) still threatens the feasibility of in-situ

manufacturing in space.

From a social perspective, AM technology still

faces delays in standardization and quality

certification systems. For example, although Xi’an

Plittech Company has improved the fatigue life of

titanium alloy components by 30% through process

optimization, the industry still lacks universal

standards covering the entire chain of "materials-

processes-testing." The previously mentioned

ISO/ASTM 52900 has established a framework of

seven basic process categories, but it has not detailed

the process parameter specifications for specific

material-equipment combinations, resulting in

varying output quality from similar equipment

produced by different manufacturers.

From an environmental perspective, sustainability

challenges are issues that AM technology cannot

ignore. Although AM increases material utilization

rates to over 90% through on-demand production and

promotes the use of bio-based resins and recycled

metal powders, the energy consumption of metal

powder atomization accounts for 35%-50% of the

total energy consumption in the production process,

while the energy efficiency of laser melting processes

is only one-third that of traditional forging. At the

same time, although related companies have reduced

carbon emissions by 18% through equipment

renovation programs, the global AM industry still

consumes an amount of electricity equivalent to the

output power of a medium-sized thermal power plant

annually.

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