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.

The quality and efficiency of Fused Deposition Modelling (FDM) 3D printing are highly dependent on the careful selection of process parameters such as layer height, infill density, print speed, and nozzle temperature. The standard parameter tuning processes are mostly rule-based and time-consuming, frequently involving much trial-and-error process. The paper proposes an AI-based framework of multi-objective optimization of 3D printing conditions, which is based on machine learning and evolutionary method. It was produced systematically as a result of experimentation, and it reflected the relationships between process control parameters and the most important measures of performance such as tensile strength, surface roughness, and the time it takes to print. Supervised learning algorithms, especially Random Forest and Boost, were able to predict very well (R 2 > 0.85). Integration of these models with NSGA-II was used to find Pareto-optimal sets of parameters that showed trade-offs between the performance and efficiency. The experimental verification revealed that AI-optimized settings demonstrate good results in performance compared to the default settings provided in a slicer, being more than 20% stronger, providing an improvement in finish and speed. The study has a contribution to the intelligent additive manufacturing, as it allows the controlled tuning of parameters automatically, precisely, and at scale.

The rapid growth of 3D printing technology has revolutionized manufacturing across various sectors, but its environmental impact due to the use of petroleum-based plastics has raised concerns. This review will look at the advancements in the production of highly biodegradable and sustainable materials used in 3D printing including polymers made using renewable sources i.e.; polylactic acid (PLA), polyhydroxyalkanoates (PHA) and polycaprolactone (PCL), and composite materials using natural fibers and fillers produced using wastes. Their biodegradability, mechanical properties and printability are explored, as well as their actual applications in the biomedical industry, consumer goods, packaging and construction industries. In addition, it speaks about descending trends in innovative materials, recycling methods, and advanced composites pointing at the possibility to use these materials as a part of the circular economy. Despite these issues, like the cost and performance restrictions, the current trends of developments in material science and processing technologies promise the aspect of sustainable 3D Printing. This summary case identifies the growing significance of using eco-friendly materials in such practices as additive manufacturing to promote environmental consideration in the production procedure.

The integration of generative design with additive manufacturing (AM) represents a significant advancement in digital fabrication and product optimization. The study at hand represents a comparative analysis of four most popular generative design software packages, including Autodesk Fusion 360, topology, Siemens NX, and SolidWorks/3DXpert, with regard to their relevant use and performance in AM workflows. Each of the tools was evaluated using standardized case studies and functional models in terms of usability, optimization, simulation integration, and AM compatibility, and output quality. The quantitative material consumption, weight decrease and print time were assessed together with the qualitative user feedback so as to generate a holistic analysis. The findings indicate that although all platforms have the ability to generate AM-ready components, they are all superior in different ways with respect to complexity, control, and integration of workflow. The paper puts a lot of stress on accurate software selection in association with design requirements and the capabilities of an organization. It is also the description of limitations and possibilities to achieve better interoperability, simulation accuracy, and automation existing now and in the future. The proposed work offers a workable guideline to engineers, designers, and other researchers desiring to implement or evaluate the use of generative design in AM-driven product development.

The integration of topology optimization, generative design, and additive manufacturing is transforming the field of engineering design by enabling the creation of highly efficient, lightweight, and complex structures. Topology optimization is based on mathematical workflow to determine the most desirable material distribution whereas, generative design involves such a wide variety of performance-based geometries created on the basis of user-specified objectives. Additive manufacturing does supplement such methods by offering the possibility to realize complex shapes that otherwise cannot be manufactured physically. This article discusses the concepts of topology and generative optimization and their distinct and synergistic capabilities and, in practice, how to take advantage of them with 3D printing technologies. Aerospace, automotive, medical, and consumer case studies show the pros and cons of such an integrated workflow. The paper ends by stating some of the main limitations and outlining the future areas of research to strengthen the use and success of this revolutionary design-manufacturing design.