Large-format additive manufacturing of polymers: a review of fabrication processes, materials, and design

Large-format 3D printing for polymers enables cost-effective mass customisation and production of structurally robust, large-scale components for industries like aerospace and automotive. This review analyses additive manufacturing scalability, including throughput, volume, and essential criteria for 3D printing techniques. Challenges in large-scale polymer additive manufacturing are explored, including material selection, interlayer bonding, surface quality versus production speed, recyclability of materials, and post-processing. Materials development is found to be crucial for addressing thermal shrinkage issues, with solutions involving process control and fibre reinforcement while considering rheological properties and nozzle clogging. Balancing production speed and surface finishing in material extrusion 3D printing involves factors like print speed, nozzle size, and innovative designs to optimise throughput and surface quality. In large-format 3D printing, meticulous process control and quality assurance are vital to ensure the expected printing outcomes and defect-free parts, given the substantial material and energy investment.