V1I3P6

3D-Printed Functional Coatings Using Additive Manufacturing Techniques

Daniel Ifeoluwa Ajiola^1*, Akintomide Adebile² , Emmanuel Omeiza Ajoge³, Julius Adeyera A.⁴, Chukwunonso Ikedionu⁵

Abstract

Additive manufacturing (AM) techniques have revolutionized the fabrication of functional coatings by enabling precise control over composition, microstructure, and architecture at micro- to nanoscale. This review provides a comprehensive overview of the latest advances in 3D-printed functional coatings, emphasizing key additive manufacturing methods such as inkjet printing, aerosol jet printing, direct ink writing, and laser-based techniques. The materials employed—including polymers, ceramics, metals, composites, and nanomaterials—are examined in relation to their processing challenges and performance attributes. Applications spanning aerospace, automotive, biomedical implants, electronics, sensors, and energy devices are discussed to illustrate the transformative impact of AM on coating functionalities. Furthermore, critical challenges such as resolution, material compatibility, and scalability are analyzed. Future trends highlighting hybrid manufacturing approaches, smart and responsive coatings, and sustainability considerations underscore the evolving landscape of this field. This review aims to guide researchers and industry professionals in harnessing additive manufacturing for innovative, multifunctional coatings with enhanced performance and environmental compatibility.

Keywords:

Additive manufacturing, 3D printing, Functional coatings, Inkjet printing, Aerosol jet printing, Direct ink writing, Laser-based techniques