Sustainable Additive Manufacturing of Polymer Composites: A Review

Authors

Wan Sharuzi Wan Harun, Automotive Engineering Centre, Universiti Malaysia Pahang Al-Sultan Abdullah, 26600, Pekan, Pahang, Malaysia; Faculty of Mechanical and Automotive Engineering Technology, Universiti Malaysia Pahang Al-Sultan Abdullah, 26600, Pekan, Pahang, Malaysia; Department of Mechanical Engineering & AND Director–Centre for Sustainable Materials and Surface Metamorphosis (CSMSM), Chennai, IndiaFollow
Faiz Ahmad, Department of Mechanical Engineering, Faculty of Engineering, Universiti Teknologi PETRONAS, Perak, MalaysiaFollow
Farhana Mohd Foudzi, Department of Mechanical and Manufacturing Engineering, Faculty of Engineering and Built Environment, Universiti Kebangsaan Malaysia, 43600 Bangi, Selangor, MalaysiaFollow
Fujio Tsumori, Department of Mechanical Engineering, Faculty of Mechanical Engineering, Kyushu University, 744 Motooka, Nishi-ku, Fukuoka, 819-0395, JapanFollow
Arun kumar Thirugnanasambandam, Department of Mechanical Engineering & AND Director–Centre for Sustainable Materials and Surface Metamorphosis (CSMSM), Chennai, IndiaFollow
Mohammed Saber, Department of Mechanical Engineering, College of Engineering, King Faisal University, PO Box 380 Al-Ahsa 31982, Kingdom of Saudi ArabiaFollow

Abstract

Additive Manufacturing (AM) of polymer composites has matured from a prototyping tool into a viable process for functional components. This review critically assesses this progress, focusing on the intersection of performance, sustainability, and industrial readiness. Advancements in AM processes now accommodate diverse reinforcements, from nanoscale fillers to continuous fibres, yielding parts with exceptional mechanical properties. Concurrently, a sustainability strategy has emerged, prioritising bio-based and recycled feedstocks, enhanced process energy efficiency through novel out-of-oven curing, and circular economy principles. However, widespread industrial adoption is hindered by persistent challenges. These include managing fibre-matrix interfacial integrity, the inherent anisotropy of printed parts, complex qualification pathways, and the end-of-life conundrum for composite waste. To overcome these barriers, future research must pivot to integrated, data-driven approaches. Leveraging computational optimisation and artificial intelligence is essential to navigate the trade-offs between performance, cost, and lifecycle sustainability, and ultimately resolve the certification paradox to unlock the full potential of this transformative technology.

First Page

75

Last Page

92

Recommended Citation

Harun, Wan Sharuzi Wan; Ahmad, Faiz; Foudzi, Farhana Mohd; Tsumori, Fujio; Thirugnanasambandam, Arun kumar; and Saber, Mohammed (2025) "Sustainable Additive Manufacturing of Polymer Composites: A Review," The Nexus of Sustainability and Energy Technology Journal: Vol. 1: Iss. 2, Article 2.
DOI: https://doi.org/10.63100/3080-1915.1006