Revolutionizing manufacturing: A comprehensive overview of additive manufacturing processes, materials, developments, and challenges

Additive manufacturing (AM) technology has revolutionized the way goods are developed and produced, with numerous uses in aerospace, automotive, medical, and consumer goods industries. Its significance within the context of the fourth industrial revolution, characterized by digitalization, automation, and interconnected systems, is imperative. This paper provides a comprehensive overview of the current state of AM, including its background, underlying concepts, processes, materials, implicit benefits, and inherent limitations. It also examines the various applications of AM for the manufacture and remanufacture of parts, components, and products. This study assesses current advances in AM, such as progress in multi-material and large-scale 3D printing, improvements in speed and efficacy, precision and accuracy, automation, and sustainability. Likewise, the study investigates some of the present issues confronting AM, such as material limits, cost, intellectual property, and sustainability. Furthermore, by analyzing the review articles on various aspects of AM, this paper provides a more comprehensive overview of the subject. Finally, the study concludes with highlights of future prospects and emerging AM trends. This comprehensive review is intended to offer readers a clear grasp of AM, its inherent processes, and recent advances, as well as the challenges that must be addressed in order to fully realize the possibilities it holds.