Powder-Based Additive Manufacturing: A Critical Review of Materials, Methods, Opportunities, and Challenges

As a 0D material, powder particles can be used to create almost any complicated engineering component by utilizing the high-performance manufacturing capabilities of additive manufacturing (AM). Although powder-based AM methods provide an outstanding practical value and development for modern manufacturing world, they continue to face challenges such as a lack of accessible categories, temperature restrictions, and poor performance of molded components. Therefore, researching for new AM materials and procedures has become an extremely necessary endeavor. For this purpose, a firm grasp of the current state of the art of powder-based AM technologies is imperative. Hence, herein, a comprehensive review is presented on the most widely used powder-based AM methods, and the materials used by these methods. For each method, the development and current state, operating principles, limitations, and future prospects are summarized. In contrast, for materials, their classifications, properties, and preparation methods are explored in great detail, while also commenting on the specific compatibilities between powder materials and powder methods. Industrial and commercialized applications of powder-based AM are also presented in this work. Finally, the limitations of the current powder-based technologies are highlighted, with comments regarding the future of this field.