Additive Manufacturing of Functionally Graded Materials

Summary

Additive manufacturing of functionally graded materials (FGMs) combines layer-by-layer fabrication with spatial control of composition and microstructure to produce components whose properties evolve gradually across their volume. By tailoring material gradients, it is possible to mitigate stress concentrations at interfaces, balance strength and ductility, and integrate disparate functions within a single part. Techniques such as powder-bed fusion, directed energy deposition and material jetting enable seamless transitions between metals, polymers and ceramics, opening new avenues in aerospace, automotive, biomedical implants and energy applications. Advances in multi-scale design frameworks, in situ process monitoring and computational thermodynamics have accelerated the optimisation of thermal histories and compositional profiles. These developments promise lighter, more durable structures, corrosion-resistant coatings and bespoke functional devices, underlining the global significance of graded architectures in modern engineering.

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Additive Manufacturing of Functionally Graded Materials publication trend

The graph below shows the total number of articles in additive manufacturing of functionally graded materials across all publications each year (not limited to Nature Index journals).

Technical terms

Additive manufacturing (AM): A suite of processes that build components layer by layer from digital models, enabling complex geometries and material combinations.

Functionally graded material (FGM): A composite in which composition, structure or properties vary gradually over volume to achieve spatially tailored performance.

Directed energy deposition (DED): An AM technique in which focused energy melts feedstock material as it is deposited, allowing in situ alloying and gradients.

Thermodynamic modelling: Computational prediction of phase equilibria and transformations used to design crack-resistant composition paths in graded materials.

References

  1. A Review on Functionally Graded Materials and Structures via Additive Manufacturing: From Multi‐Scale Design to Versatile Functional Properties. Advanced Materials Technologies (2020).
  2. Local composition detouring for defect-free compositionally graded materials in additive manufacturing. Materials Research Letters (2023).
  3. A functionally graded material design from stainless steel to Ni-based superalloy by laser metal deposition coupled with thermodynamic prediction. Materials & Design (2022).

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