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Open research questions in Additive Manufacturing and 3D Printing Technologies

214 unresolved questions extracted from the limitations and future-work sections of 960 Additive Manufacturing and 3D Printing Technologies papers in our library. Each links back to the study that raised it.

What the literature leaves open

  • The need to redesign manufacturing systems toward more efficient, circular models. The lack of comparative studies on the carbon footprint and production cost of TPU–Al composite specimens manufactured by fused filament fabrication using different aluminum-powder sourcing routes.

    University Laboratory-Scale Carbon Footprint and Cost Comparison of Atomized and Short-Chip-Milled Aluminum Powders for TPU–Al Composite Specimens · 2026 · DOI

  • The study identifies a gap in the understanding of the effects of post-curing atmosphere and thermal aging on 3D-printed splint material. The research aims to address this gap by investigating the surface characteristics and mechanical properties of the material.

    Effects of post-curing atmosphere and thermal aging on the physico–mechanical properties of a 3D-printed splint material · 2026 · DOI

  • While numerous studies have focused on individual aspects of the FFF process in fabrication of such structures, detailed review linking design strategies, optimization techniques, and manufacturing challenges are scarce.

    A review of design and fabrication strategies for thermoplastic lightweight thin-walled stiffened shells and lattice structures utilizing fused-filament fabrication (FFF) · 2026 · DOI

  • High Resolution Image Download MS PowerPoint Slide Acrylonitrile–styrene–acrylate (ASA) is a material with high potential, making it suitable for outdoor applications, which warrants further investigation.

    Optimization of Roughness, Dimensional Conformity, and Porosity of 3D-Printed ASA with MEX: Impact of Critical Process Control Parameters · 2025 · DOI

  • No studies are proposing a machine learning approach focused on different phases of the product lifecycle, from the early design phase to manufactured parts.

    Machine learning in design for additive manufacturing: A state-of-the-art discussion for a support tool in product design lifecycle · 2025 · DOI

  • Moreover, future research will explore cutting-edge technological advancements to enhance these properties and meet the growing demands of modern industry.

    A review of the influence of sand properties on parts manufactured by rapid sand casting through additive manufacturing · 2025 · DOI

  • Future research should focus on improving the algorithmic transparency of commercial software, increased flexibility to add manufacturability constraints, and potentially including sustainability models to enhance the intelligence in design-to-manufacturing workflows.

    Intelligent manufacturing paradigms: linking design optimization and sustainability in large-area additive manufacturing · 2025 · DOI

  • Additionally, it underscores the need for further research into long-term powder recycling strategies, including controlled rejuvenation methods, advanced monitoring techniques, and predictive models for powder degradation.

    Reuse powder impacts in additive manufacturing for aeronautical parts · 2025 · DOI

  • While much research has focused on preceramic filament formulations, process feasibility, and bulk mechanical properties, the capacity of FFF to produce intricate ceramic shapes, such as gyroids, remains underexplored.

    Evaluating geometric conformity and compressive properties of black zirconia gyroid structures obtained through fused filament fabrication · 2025 · DOI

  • The application of bamboo powder in PLA matrices for 3D printing applications is still underexplored, with only a few comparative studies across different manufacturing techniques conducted so far.

    Effect of filler characteristics and processing route on bamboo powder-reinforced PLA composites · 2025 · DOI

  • Although desktop-size material extrusion additive manufacturing is increasingly adopted for biomass-polymer-based composites, the potential of large-format direct extrusion 3D printing systems remains unexplored.

    PLA Feedstock Filled with Spent Coffee Grounds for New Product Applications with Large-Format Material Extrusion Additive Manufacturing · 2024 · DOI

  • Unlike traditional monolithic materials, composites exhibit complex behaviour and inconsistent results during machining.

    Subtractive manufacturing of composite materials with robotic manipulators: a comprehensive review · 2024 · DOI

  • These findings underscore the need for further investigation into the cumulative health impacts of prolonged exposure to multiple VOCs.

    Analysis of Volatile Organic Compound Emissions in 3D Printing: Implications for Indoor Air Quality · 2024 · DOI

  • The lack of a numerical-experimental model that estimates the thermal profile of customized and modular equipment for extrusion-based AM. The need for a more accurate and reliable method for monitoring and controlling the temperature profile during the extrusion process.

    Numerical analysis and experimental evaluation of temperature profile in a miniaturized screw-assisted 3D print head · 2026 · DOI

  • The influence of structural elements acting as preferential heat conduction paths between modules is analyzed, with special emphasis on the inlet region where temperature control is critical for processing temperature-sensitive polymers like polycaprolactone (PCL).

    Numerical analysis and experimental evaluation of temperature profile in a miniaturized screw-assisted 3D print head · 2026 · DOI

  • Complex mechanical-thermal interactions in 3D printing. Non-linear nature of the process. Need to optimize the tensile properties of 3D printed parts.

    Modelling of tensile strength of 3D printed PETg, ABS and ASA based novel filament · 2026 · DOI

  • Earlier researches focused on evaluation of mechanical properties of a single material. There is a need to model the tensile behaviour of novel filaments with emphasis on material composition and mechanical performance.

    Modelling of tensile strength of 3D printed PETg, ABS and ASA based novel filament · 2026 · DOI

  • Further research can be conducted to optimize the 3D printing process for specific materials and applications. The use of other optimization algorithms can be explored. The study of other FDM materials can be conducted.

    Parametric Evaluation of Mechanical and Surface Characteristics in FDM-Based 3D Printing · 2026 · DOI

  • The study identifies a gap in the optimization of surface roughness, shear strength, and wear resistance for FDM materials. The use of a Genetic Algorithm can help to find the best parametric combination for specific objectives.

    Parametric Evaluation of Mechanical and Surface Characteristics in FDM-Based 3D Printing · 2026 · DOI

  • The study is limited by the small dataset size. The experimental dataset was based on a L32 Taguchi design. No tuning was done against the test set.

    Physics-Aligned Data Augmentation for Reliable Property Prediction in Direct Ink Writing Under Extreme Data Scarcity · 2026 · DOI

  • Future research can explore the application of the proposed framework to other additive manufacturing techniques. The use of other generative models can be investigated. Further studies can focus on improving the physics consistency of the augmented data.

    Physics-Aligned Data Augmentation for Reliable Property Prediction in Direct Ink Writing Under Extreme Data Scarcity · 2026 · DOI

  • The paper highlights the lack of standards in data/integration and process qualification as a significant limitation. The industry's fragmentation and the need for open architectures or middleware are also mentioned as limitations. The paper does not provide a comprehensive account of known limitations.

    Intelligent composite 3D printing: the role of artificial intelligence, machine learning, and in-situ monitoring in next-generation additive manufacturing · 2026 · DOI

  • The paper suggests that future research should focus on developing open architectures or middleware to enable the integration of AI/ML with composite AM. The need for further research on digital twin frameworks and their application in composite AM is also highlighted. The paper does not provide a comprehensive list of future research directions.

    Intelligent composite 3D printing: the role of artificial intelligence, machine learning, and in-situ monitoring in next-generation additive manufacturing · 2026 · DOI

  • The relatively limited dataset size was intentionally selected to support preliminary pilot experiments. The study focused on a specific type of additive manufacturing, Fused Filament Fabrication.

    Integrating Image Processing and Machine Learning to Predict Failures in Additive Manufacturing · 2026 · DOI

  • Future research can focus on applying the study's approach to other types of additive manufacturing. Future research can explore the use of other machine learning techniques, such as unsupervised learning approaches. Future research can investigate the application of the study's approach to other industries and domains.

    Integrating Image Processing and Machine Learning to Predict Failures in Additive Manufacturing · 2026 · DOI

Most-cited papers in Additive Manufacturing and 3D Printing Technologies

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214 open questions have been extracted from the limitations and future-work passages of 960 Additive Manufacturing and 3D Printing Technologies papers in our library. Each one below links back to the study that raised it, so you can read the original claim in context.

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