Principles of material extrusion in metal additive manufacturing

Abstract

This study aims to examine the potential effects of additive manufacturing (AM) technology on the principles of metal material extrusion. Additive manufacturing, also known as 3D printing, is an advanced manufacturing method that enables the production of three-dimensional objects by combining materials layer by layer. Compared to traditional extrusion methods, additive manufacturing allows for the production of complex geometries and customized designs more easily and flexibly. In this study, the principles of additive manufacturing technology and various metal extrusion methods were examined, and the potential for combining these two technologies in industrial applications was investigated. The advantages of AM in this field are discussed by examining the extrusion process of metal materials and the difficulties encountered in traditional methods. The focus of the study is on how AM can be adapted to the metal material extrusion process and how this adaptation can be applied in industrial sectors. Additionally, the importance of design and simulation processes and material selection was emphasized. However, the potential challenges and technical limitations associated with combining additive manufacturing and metal material extrusion are also discussed. A summary is presented on the possible applications and impacts of additive manufacturing and metal material extrusion in the automotive, aerospace, medical, energy, and other industries. Additionally, speculations were made about potential future developments and innovative approaches, and how these technologies could contribute to industrial transformations was discussed. Additionally, researchers and industry professionals in the field of AM and metal material extrusion are presented with a broad perspective on the advantages and opportunities that can be obtained from combining these two technologies. As a result, it is anticipated that additive manufacturing and metal material extrusion can play important roles in future industrial applications and make production processes more efficient, flexible, and sustainable. © 2025 Elsevier B.V., All rights reserved.