Engineering Tomorrow: Optimised Materials and Surfaces for Additive Manufacturing

Abstract

Focusing on advancements in additive manufacturing, this Special Issue explores the role of novel materials and surface technologies in improving functionality, performance, and sustainability. The research papers highlight innovative approaches to understanding and overcoming material limitations, particularly in the areas of surface engineering, process optimisation, and multi-material applications. Key topics include the tribological behaviour, wear resistance, and surface quality of coated components, the effects of process parameters on mechanical strength and surface roughness, and advanced methods for surface characterisation and quality control. By addressing challenges, such as material efficiency, friction reduction, and structural integrity, the researchers emphasise the crucial role of novel materials and technologies to push the boundaries of additive manufacturing. Looking to the future, integrated strategies that prioritise sustainability, material innovation, and application-driven optimisation will be crucial. Through collaboration and technological advancement, this Special Issue provides valuable insights that will contribute to a more efficient, sustainable, and versatile future of additive manufacturing.

Additive manufacturing started as a prototyping process but due to its versatility it was introduced in various fields [1]. The versatility is highlighted not only by the variety of processes used, but with the inclusion of wide spread of materials (metals, ceramics, polymers, nanocomposites, etc.) used in manufacturing [1,2,3,4,5]. With the growing demand for sustainability and high performance, the development of innovative and functional materials, such as advanced polymers, sustainable composites and engineered coatings, has become increasingly important in additive manufacturing and related fields [6,7,8,9,10]. These innovative solutions are particularly important for industries that require improved material efficiency, enhanced mechanical properties, and reduced environmental impact, as in manufacturing, packaging and structural applications [11,12,13]. To fulfil these requirements, it is essential to address the complexity of novel materials, surface technologies, and their transformative potential for additive manufacturing. New developments, such as multi-material systems, functional coatings, and optimised composites, offer significant opportunities to overcome the limitations of conventional manufacturing processes. However, the challenges associated with material efficiency, surface quality, and recyclability continue to stand in the way of widespread application. This Special Issue addresses these critical challenges by presenting cutting-edge research and innovative approaches. Technological advances and novel strategies are expected to pave the way for more efficient, sustainable, and versatile applications in additive manufacturing.

One focus of this Special Issue is the optimisation of material performance and surface properties in additive manufacturing. Research shows the importance of understanding and improving the surface roughness, mechanical strength, and wear resistance of printed and moulded components. For example, studies on surface characterisation and quality control show how geometric features and scanning technologies affect the final performance of 3D printed parts. Process parameters, such as material deposition and layer thickness, are shown to have a direct impact on surface finish and functional performance. The research emphasises the need to fine-tune these parameters in order to achieve optimal results. In addition, the role of tribological coatings is being investigated, particularly in studies on polyethylene terephthalate glycol (PETG) parts coated with IGUS tribofilament. These studies show the potential of coating thickness and applied load to improve friction behaviour and wear resistance. These results are particularly relevant for industrial applications where surface durability and mechanical integrity are critical [11,12,13].

The second focus is on the development and evaluation of multi-material systems and thermoplastic materials to extend the functionality and versatility of additive manufacturing. Research on multi-material components produced with fused filament fabrication (FFF) provides valuable insights into the interaction between core materials such as PETG and engineering coatings that influence surface stability and friction properties. Similarly, studies on thermoplastic base polymers for prosthetics show how processing parameters affect key properties such as surface roughness, hardness, and moisture absorption, demonstrating the wider applicability of additive and injection moulding-based manufacturing processes. These studies emphasise the need for innovative solutions to overcome existing limitations, with a focus on achieving a balance between mechanical performance, functional properties, and material efficiency [12,13,14].

The research presented in this issue highlights advances in material science and process optimisation, offering opportunities to improve surface functionality, wear resistance, and overall performance in additive manufacturing applications.

Regarding future research efforts, it is important to emphasise the importance of integrated approaches that take into account the entire life cycle of the materials used in additive manufacturing. From material selection and process optimisation to performance evaluation and recyclability, sustainability and innovation must remain key priorities. Exploring advanced solutions, such as multi-material systems, tribological coatings, and process-controlled surface enhancements, will enable the full potential of additive manufacturing to be realised across industries.

This Special Issue provides an excellent platform for researchers and practitioners to explore the latest advances in novel materials and surface technologies for additive manufacturing. By covering topics ranging from mechanical and chemical properties to surface quality, wear resistance, and multi-material functionality, we aim to foster a deeper understanding of the challenges and opportunities of this rapidly evolving field.