Advances in Nanocomposite Materials for Additive Manufacturing: A Review of Materials, Methods, and Applications

Abstract:

Additive manufacturing (AM), or 3D printing, has rapidly advanced from prototyping to functional part fabrication, driven by its ability to produce complex geometries with minimal material waste. A critical enabler of next-generation AM applications is the integration of nanocomposite materials—engineered by incorporating nanoscale fillers into polymeric, metallic, or ceramic matrices. These nanocomposites offer enhanced mechanical, thermal, electrical, and biological properties, unlocking multifunctional capabilities for a wide range of industries, including aerospace, biomedical, electronics, and energy. This review provides a comprehensive overview of the types of nanocomposites and nanofillers used in AM, examines their compatibility with various AM techniques, and explores the functional enhancements they bring. Key application areas and the associated challenges in processing, scalability, and safety are discussed. The article concludes with insights into future trends, emphasizing the transformative role of nanocomposites in advancing AM toward high-performance, intelligent, and sustainable manufacturing solutions.