Open research questions in Additive Manufacturing and 3D Printing Technologies
771 gap statements mined from Additive Manufacturing and 3D Printing Technologies papers in our 7.9M-paper local library, which holds 5,507 papers on the topic — drawn mostly from each paper's own stated research gap, future-work, challenge and limitation notes, and its abstract. The ones listed below are a selection still marked open; each names the study that raised it, with a DOI link where the paper has one.
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What the literature leaves open
Accurate colour reproduction in dental restorations is challenging due to the complex factors affecting tooth appearance. Existing approaches have limitations, such as manual staining and characterisation techniques being time-consuming and reliant on specialised personnel.
The need to compensate for selected changes, such as mass, in additive manufacturing.
The need to develop shape-memory polymers with consistent and reliable properties.
Tailoring mechanical and functional properties of Thermoplastic Polyurethane (TPU) filaments for additive manufacturing: A review of blends and additives · 2026 · DOIThe need to optimize process parameters for improved structural integrity and reliability of 3D printed components. The lack of understanding of the impact of layer thickness, nozzle temperature, and infill density on tensile properties of PET-G material.
Optimization of 3D printing process parameters for improvement of tensile properties of fabricated polyethylene terephthalate glycol (PET-G) material · 2026 · DOIThere is a knowledge gap regarding the performance of wood-based polymer composites under the thermal and mechanical conditions unique to LSAM. Most available data on the mechanical properties of WPCs are obtained from injection-moulded specimens or parts produced on small-scale 3D printers, which may not accurately represent the performance of structures fabricated in larger formats with larger tooling systems.
Physico-mechanical and anisotropic performance of robotic large-scale additive manufacturing using sustainable wood-based PLA composites · 2026 · DOIThe lack of standardized protocols or guidelines for the design, fabrication, and quality control of 3DP-PoCT devices. Consistency and reliability in diagnostic results are essential for clinical applications, but without standardized processes, there is a risk of variability in device performance.
The gap identified by the paper is the need for efficient CAD optimization methods for FFF pre-processing, particularly for parts with lattice structures. The paper highlights the challenges of removing supports from parts with complex structures.
CAD Analysis of 3D Printed Parts for Material Extrusion—Pre-Processing Optimization Method · 2025 · DOIThe structure of the material obtained with 3D printing technology is not uniform, making it difficult to determine the strength properties. Current FFF 3D printing technologies cannot achieve high accuracy and small clearances without additional post-processing. There is a need for new design principles and methods for creating assembled rotational joints using 3D printing technology.
An Approach for Designing 3D-Printed Assembled Rotational Joints and Assemblies for Mechanisms and Robot Models · 2025 · DOIThe inherent heterogeneity of natural fibers can lead to variability in the composite microstructure. The study identifies the need to balance reducing statistical uncertainty with addressing practical constraints, such as availability of fibers and filament stability. The challenge of maximizing fiber-matrix interactions to achieve substantial improvements in mechanical properties is identified.
Enhancing Mechanical Properties of 3D-Printed PLA Composites Reinforced with Natural Fibers: A Comparative Study · 2025 · DOIWarpage and mechanical property variations remain significant challenges in 3D printing PEEK parts. Layer bonding issues can lead to brittleness and reduced ductility in 3D-printed PEEK components. The optimization of printing settings for PEEK components is a complex task due to the numerous parameters involved.
Effect of Printing Parameters on Mechanical Properties and Warpage of 3D-Printed PEEK/CF-PEEK Composites Using Multi-Objective Optimization Technique · 2025 · DOIExplore sustainable practices in CNC post-processing, investigate novel toolpaths and cutting strategies specifically tailored to the characteristics of FDM materials, and address the challenges of scaling hybrid manufacturing for medium to high-volume production.
The surface quality and dimensional accuracy of FDM-printed parts are not sufficient for high-performance and precision-driven industries. There is a need for post-processing techniques to improve the surface finish and dimensional precision of FDM parts. The integration of subtractive CNC machining with additive FDM printing is a viable solution to address these limitations.
The existing problems in the current research were pointed out, - The future development trends were prospected, - The development and engineering application of additive manufacturing technology for wire-based multi-metal structures need to be promoted.
The need for a comprehensive process–structure–performance framework for wire-based additive manufacturing of multi-material structures. The lack of understanding of the effects of wire feeding methods and directions on the properties of multi-material structures.
Existing approaches for partitioning and consolidating components are not applicable in early or greenfield product development. The creation and validation of the active surface groups of one design variant are time-consuming. A manual exploration of all design variants is not feasible.
One solution to the issues of 3D printing is the multi-objective optimization method, which can optimize parameters related to mechanical characteristics and production costs. Another main research direction focuses on improving the aesthetic properties of 3D-printed parts.
CAD Analysis of 3D Printed Parts for Material Extrusion—Pre-Processing Optimization Method · 2025 · DOIInvestigating metamerism in the colour optimisation - Extending the framework beyond dental applications - Using comparable sets of biocompatible…
Experimental mechanics with additive manufacturing - Further research on the application of FAIR data principles to experimental…
Further research is needed to investigate the effect of other process variables on the tensile properties of 3D printed PET-G material - Research is needed to validate the results of this study using a larger sample size - The development of new methods for optimizing 3D printing process parameters could be a direction for future…
Optimization of 3D printing process parameters for improvement of tensile properties of fabricated polyethylene terephthalate glycol (PET-G) material · 2026 · DOIInvestigation of other wood-based polymer composites, - Comparison to other manufacturing methods, - Long-term testing of printed products, - Expansion of printing orientation…
Physico-mechanical and anisotropic performance of robotic large-scale additive manufacturing using sustainable wood-based PLA composites · 2026 · DOIInvestigating the effects of other environmental factors on nylon filament. Developing operational guidelines or standards for handling and storing nylon filaments. Examining the effects of moisture on other types of 3D printing materials.
The longevity and accuracy of sensors remain a challenge - The algorithms that convert sensor readings into the actual temperature must be appropriate for the actual conditions - Calibration of infrared cameras is necessary to avoid emissivity…
Technical limitations such as material availability, scalability, certification, and cost competitiveness, - Economic limitations such as high production costs, - The need for integration with renewable energy sources and recycling…
Additive Manufacturing as a Catalyst for Low-Carbon Production and the Renewable Energy Transition in Electric Vehicles · 2025 · DOIInvestigating the mechanical behavior of 3D-printed Nylon 12 Carbon Fiber specimens under different loading conditions, - Examining the effects of varying printing parameters on the mechanical properties of 3D-printed specimens, - Developing more advanced material models for finite element…
Determination of the Mechanical Tensile Characteristics of Some 3D-Printed Specimens from NYLON 12 CARBON Fiber Material · 2025 · DOINatural fiber reinforcements often increase heterogeneity in the composite microstructure, - The improvement in stiffness should be characterized as moderate rather than substantial, - Further enhancement may require advanced surface treatments or compatibilizers to maximize fiber-matrix…
Enhancing Mechanical Properties of 3D-Printed PLA Composites Reinforced with Natural Fibers: A Comparative Study · 2025 · DOI
Most-cited papers in Additive Manufacturing and 3D Printing Technologies
- 3-D printing: The new industrial revolution · Business Horizons · 2011 · 2,063 citations
- The rise of 3-D printing: The advantages of additive manufacturing over traditional manufacturing · Business Horizons · 2017 · 1,649 citations
- 3D printing with polymers: Challenges among expanding options and opportunities · Dental Materials · 2015 · 1,530 citations
- Direct Ink Writing: A 3D Printing Technology for Diverse Materials · Advanced Materials · 2022 · 1,303 citations
- The future of dental devices is digital · Dental Materials · 2011 · 1,155 citations
- Additive manufacturing of advanced ceramic materials · Progress in Materials Science · 2020 · 840 citations
- A Review of Vat Photopolymerization Technology: Materials, Applications, Challenges, and Future Trends of 3D Printing · Polymers · 2021 · 798 citations
- Direct Ink Writing of Three‐Dimensional Ceramic Structures · Journal of the American Ceramic Society · 2006 · 752 citations
- Advances in Metal Additive Manufacturing: A Review of Common Processes, Industrial Applications, and Current Challenges · Applied Sciences · 2021 · 721 citations
- Recent Progress on Polymer Materials for Additive Manufacturing · Advanced Functional Materials · 2020 · 700 citations
Most recent work
- Polymer Composites in Additive Manufacturing: Current Technologies, Applications, and Emerging Trends · Polymers · 2026
- Lithographic crystallinity regulation in additive fabrication of thermoplastics (CRAFT) · Science · 2026
- Roadmap on Artificial Intelligence‐Augmented Additive Manufacturing · Advanced Intelligent Systems · 2026
- Generative design strategies for additive manufacturing of lattice structures: A review · Materials & Design · 2026
- Optimizing 3D printing parameters for enhanced tensile strength and efficiency using machine learning models · Progress in Additive Manufacturing · 2026
- Intra-filament voids in FDM 3D-printed continuous carbon fiber composites: microstructure, quasi-static/dynamic mechanical properties, and damage mechanisms · Composite Structures · 2026
- Tribo-mechanical performance and microstructural characterization of FDM printed PLA and ABS components · Journal of Materials Research and Technology · 2026
- Multifactor-constrained path planning method for high-quality additive manufacturing of continuous fiber-reinforced composites thin-walled structures · Composites Part B Engineering · 2026
- Interlayer bonding in vat photopolymerization additive manufactured ceramics with enhanced mechanical properties · Journal of Advanced Ceramics · 2026
- Optimization window of printing parameters for specific strength and energy consumption in PEEK additive manufacturing · Materials and Manufacturing Processes · 2026
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