Review on

Multi-material
3D Printing:
Methods,
applications
and challenges
Paper ID: MEA 5

Submitted by:

1. Sumith Naik :

USN: 2GI20AE040, Dept. of Aeronautical Engineering, KLS GIT

2. Mohit Hiremath :

USN: 2GI21EC067, Dept. of E & C Engineering, KLS GIT.

Table of Contents
I. INTRODUCTION ---------------------------------------------------------------------------------------- 4
II. METHODS OF OPERATION --------------------------------------------------------------------------- 4
A. Material Extrusion (ME) --------------------------------------------------------------------------- 4
B. Material Jetting (MJ) ------------------------------------------------------------------------------- 5
C. Direct Ink Writing (DIW) --------------------------------------------------------------------------- 5
D. Vat Polymerisation---------------------------------------------------------------------------------- 5
E. Direct Energy deposition -------------------------------------------------------------------------- 6
III. SUSTAINABILITY ------------------------------------------------------------------------------------- 6
A. Environmental Sustainability --------------------------------------------------------------------- 6
B. Economic Sustainability --------------------------------------------------------------------------- 6
C. Social Sustainability --------------------------------------------------------------------------------- 7
IV. ADVANTAGES AND DISADVANTAGES ---------------------------------------------------------- 7
V. APPLICATIONS ------------------------------------------------------------------------------------------ 8
A. MMAM of electronic components -------------------------------------------------------------- 8
B. Multi-material bioprinting ------------------------------------------------------------------------ 8
C. Soft robotics ------------------------------------------------------------------------------------------ 8
VI. FUTURE SCOPE--------------------------------------------------------------------------------------- 9
A. Integration of material gradients at different length scales ------------------------------ 9
B. Hybrid/dissimilar material systems ------------------------------------------------------------- 9
C. Design for multi-materials ------------------------------------------------------------------------ 9
VII. CONCLUSION ----------------------------------------------------------------------------------------10
VIII. REFERENCES -----------------------------------------------------------------------------------------10

2
LIST OF FIGURES
FIGURE 1. MATERIAL EXTRUSION [3] ....................................................................... 5
FIGURE 2. MATERIAL JETTING [3]............................................................................ 5
FIGURE 3. DIRECT INK WRITING [3] ......................................................................... 5
FIGURE 4. DIRECT ENERGY DEPOSITION [3] ............................................................... 6
FIGURE 5. ENERGY HARVESTER DEVICE ..................................................................... 8
FIGURE 6. MULTI-MATERIAL LIGHT-BASED ADDITIVE MANUFACTURING OF EMBEDDED
CARBON NANOCOMPOSITE STRUCTURES WITH MULTI-MATERIAL DIGITAL LIGHT
PROCESSING. [2] ............................................................................................. 9
FIGURE 7. END EFFECTOR USING PLA AND TPU MATERIAL ........................................... 9

3
 Review on Multi-material 3D Printing: Methods,
applications and challenges
Sumith Naik Mohit Hiremath
Department of Aeronautical Engineering, KLS GIT Department of Electronics and Comm. Engineering, KLS GIT
Email :[email protected] Email :[email protected]

Abstract — A ground-breaking innovation that has hull of the part, it is also possible to minimize the quantity of
transformed additive manufacturing is multi-material 3D post-processing required.
printing. This paper offers a thorough investigation of this
cutting-edge topic, covering different approaches, sustainability The creation of 3D-printed prosthetics frequently makes use
issues, benefits, drawbacks, applications, and concluding
thoughts. Beginning with an explanation of the many ways used
of multi-material 3D printing technologies. It permits the use
in multi-material 3D printing, from inkjet-based strategies to of various materials, such as rigid carbon fibre for the
extrusion-based procedures, the study then focuses on each prosthesis' body and soft TPU for the contact points with the
approach's distinct advantages and disadvantages. It also body. Therefore, the prosthetics can be modified to meet a
explores the value of exact material deposition and the person's various demands and preferences. The creation of
difficulties in achieving it. synthetic tissue architectures has other medical applications.
The goal of the research is to develop tissue that resembles
The benefits of multi-material 3D printing are examined, with a human tissue in terms of feel, flexibility, and structure.
focus on its capacity to produce intricate, multi-component
Surgeons may train and learn on realistic models using such
items in a single print, opening up new design and functionality
possibilities. A variety of applications in fields including artificial tissues, which is otherwise difficult or expensive to
healthcare, aircraft, and electronics are made possible by the accomplish.
capacity to combine several materials, including conductive,
flexible, and biocompatible compounds. The report also The emphasis of current research is the development of 3D
discusses the drawbacks, such as technical difficulties with printed vaccine and medicine delivery devices. They develop
material compatibility and post-processing needs. It also talks biocompatible structures that can communicate with the
about how multi-material printing is currently constrained in human body's cells using multi-material printing.
terms of resolution and speed.
II. METHODS OF OPERATION
Keywords — 3D Printing, Multi-material additive
manufacturing (MMAM), Direct Ink writing, Material Extrusion, MMAM technology is becoming ever more popular in
sustainability, bioprinting, fused filament fabrication, soft robotics. industrial and research communities. Layer by layer, material
is added to build the desired structure to form a solid 3D
I. INTRODUCTION model. The raw material used to produce the parts includes
The additive manufacturing process of creating an object out metals, thermoplastics, hydrogels, ceramics, composites,
of numerous materials at once is known as multi-material 3D hybrids and functionally graded materials in liquid, powder
printing. It can be accomplished using techniques like Fused and solid forms.
Filament Fabrication (FFF), Selective Laser Sintering (SLA),
and Inkjet (material jetting) 3D printing, which are analogous Broadly, MMAM technology is divided into seven
to single material additive manufacturing. Extending the categories: material extrusion, vat photopolymerization,
design space to include additional materials, opens up the material jetting, direct energy deposition, sheet lamination,
possibility of producing 3D-printed items with various binder jetting and hybrid additive manufacturing. [3]
colourations or material characteristics, such as elasticity or A. Material Extrusion (ME)
solubility. In 2006, the first Fab@Home multi-material 3D ME is one of the most well-known AM methods that build
printer was made accessible to the general public. The idea components layer by layer using a variety of materials,
was swiftly embraced by the industry, and many consumer- including thermoplastics, composites, metal-filled
level multi-material 3D printers soon followed. thermoplastic filaments, and flexible elastomers. One of the
ME subcategories that use thermoplastic filament is fused
To manage the physical characteristics of a 3D-printed filament fabrication (FFF), which is schematically shown in
object, the ability to switch between different materials is Figure 1. Bead-by-bead and layer-by-layer deposition of
crucial. The user can choose between harder or softer melted filament material onto a build plate occur inside the
materials during the printing process to modify the stiffness extrusion head. The key benefits of this approach are the wide
of the thing in addition to manipulating the strength of an range of readily available materials and how easily they can
object through micro-structures. It is also used to create be modified to create unique multi-material structures.
biomimetic structures with the desired qualities by combining Modern technologies have advanced and developed to the
hard and soft materials. The appearance and haptics of the point where it is now possible to produce pieces made of
finished object can be affected by the use of materials with different materials in a single production process.
varied colours or degrees of flexibility. By selecting an
appropriate material for the support structures or the exterior

4
 liquid form. When pressure is applied, the material passes
through the nozzle after being mixed with the aid of a
revolving impeller. A graphical explanation of the DIW
procedure is shown in Figure 3. The availability of a wide
range of materials, including those with biological, structural,
and electrical capabilities, is a benefit of this technique. [3]

Figure 1. Material Extrusion [3]

B. Material Jetting (MJ)

One of the most effective and precise AM techniques is
material jetting. MJ operates on the same principles as
traditional printing equipment. Layer by layer, microdroplets
are dropped onto the build platform. The MJ technique is well
known for its ability to fabricate several materials in a single
structure. Using a jetting head, numerous photo-curable
materials are treated in this procedure. These heads each have Figure 3. Direct Ink Writing [3]
a large number of small nozzles, enabling high-resolution
printing on several different materials at once. One of the D. Vat Polymerisation
primary drawbacks of other AM methods is the inability to In contrast to other AM methods, the VAT technique utilizing
produce high-resolution materials. An illustration of this stereolithography (SLA) uses photopolymer resin to
method's schematic is shown in Figure 2. manufacture objects with high resolution and superior surface
quality. When deposited material is exposed to UV radiation,
a curing process called photopolymerization takes place.
During this process, cross connections between polymer
chains form, causing the deposited material to change from a
liquid or semi-solid state to a solid state. A graphical
explanation of the VAT procedure is shown in Figure 9. This
approach requires material interchange from one liquid resin
to another inside the vat to fabricate multi-material parts. This
method is quite time-consuming and lengthens the
manufacturing process. The VAT process uses a variety of
materials, which makes it difficult to control material
contamination. However, this method of producing multi-
material parts was just recently automated. Using a rotating
carousel mechanism, switching between materials was
mechanized in this process. On a revolving platform, many
vats with liquid resin were attached. The necessary VAT is
Figure 2. Material Jetting [3] rotated to the manufacturing platform at the time of a material
change when the laser power is utilised for additional
C. Direct Ink Writing (DIW) processing. The manufacture of transparent material and
great dimensional accuracy of the finished component are
Direct Ink Writing Among MMAM techniques, DIW is one
advantages of this procedure. The main limitations of this
of the most straightforward and accessible processes. This
technique are the extra time needed to switch between
method enables the fabrication of numerous material
materials, the fact that it can only be used with
structures at low manufacturing and material costs using a
photopolymers, material contamination, and potential waste.
wide variety of materials. Although DIW uses a heating
source to create pieces, the process operation is similar to
FFF. Instead of being introduced in solid form, the
components employed in this procedure are introduced in

5
E. Direct Energy deposition analyze the sustainability aspects of multi-material 3D
Recent developments in metal-based additive manufacturing printing, with a particular focus on its environmental,
(AM) techniques enable the direct manufacture of economic, and social implications.
heterogeneous components with complete spatial material A. Environmental Sustainability
distributions. One of the MMAM processes that can be
The environmental dimension of sustainability is of
classified as either direct metal deposition (DMD), laser-
paramount importance, especially in light of contemporary
engineered net shaping (LENS), or laser metal deposition
concerns about climate change and resource depletion. Multi-
(LMD) is DED. Wire or powder-based materials are
material 3D printing presents several environmentally
employed in this technique. In the controlled area, materials
sustainable attributes [2]:
are melted utilizing a laser, electron beam, or plasma arc
energy source. In this procedure, inert gas is employed to stop
It demonstrates a commendable level of material efficiency.
the molten pool from oxidizing.
Unlike traditional subtractive manufacturing techniques, 3D
printing, including multi-material printing, boasts minimal
material wastage. Each layer of the object is constructed with
precision, utilizing only the necessary amount of material.
This feature minimizes scrap and significantly reduces excess
material consumption.

Also, multi-material 3D printing can potentially exhibit

enhanced energy efficiency compared to conventional
manufacturing methods. It allows for the consolidation of
parts and reduces the intricacies of supply chains, resulting in
reduced energy consumption related to transportation and
logistics.

Moreover, this technology can contribute to reduced

greenhouse gas emissions. By optimizing designs and
reducing material waste, multi-material 3D printing aligns
with sustainability goals by curbing emissions during both
the manufacturing process and product lifecycle.
Furthermore, multi-material 3D printing enables localized
production, which serves as an environmentally sustainable
practice. The reduced need for long-distance shipping
Figure 4. Direct Energy deposition [3] translates into decreased emissions associated with
transportation, further emphasizing its environmental merits.
In the DED procedure, powder material is blown through
deposition nozzles where it melts and is deposited on the
substrate, layer by layer, before solidifying. The nozzle B. Economic Sustainability
rotates around the target on a multi-axis arm. Various Economic sustainability is a critical facet of any
materials, including metal wire and powder, ceramics, manufacturing process. Multi-material 3D printing holds the
functionally graded materials (FGM), metal-matrix potential to deliver significant economic advantages:
composites (MMC), and coatings, are used throughout this
process. By dynamically switching between different types of Firstly, it can substantially lower manufacturing costs. By
powders, this approach deposits them at a specified period streamlining production processes and minimizing or
during the build. The schematic representation of the DED eliminating the need for manual assembly, this technology
process with multi-material capacity is shown in Figure 4. can lead to cost reductions, particularly in labour expenses.
Being able to switch powders at any point during the process This cost-effectiveness enhances the competitiveness of
is an advantage of this method. [2] businesses utilizing multi-material 3D printing.

Moreover, multi-material 3D printing empowers companies

III. SUSTAINABILITY to offer highly customized and specialized products. This
In recent years, the evolution of 3D printing technology has customization ability not only satisfies consumer demands
led to the emergence of multi-material 3D printing, a more effectively but also reduces the need for extensive
technique that enables the simultaneous use of multiple inventories, thus decreasing inventory costs. Furthermore, the
materials within a single printing process. This innovation technology facilitates local production, which has profound
has ignited considerable interest across various industries due implications for regional economies. By bringing
to its potential to revolutionize manufacturing, offering manufacturing closer to consumers, multi-material 3D
improved product design capabilities and customization printing has the potential to stimulate economic growth,
options. However, the pursuit of these benefits raises create jobs, and reduce dependence on global supply chains,
pertinent questions about the sustainability of multi-material thereby enhancing economic sustainability.
3D printing. This research paper seeks to comprehensively

6
Nonetheless, challenges such as the significant initial need for post-processing and assembly. This simplifies
investment in equipment and the cost of materials may pose the production process and can lead to cost savings.
barriers to the widespread adoption of multi-material 3D 3. Material Optimization: Multi-material 3D printing enables
printing, particularly for smaller businesses. Additionally, precise control over the placement and distribution of
concerns regarding intellectual property protection and materials, minimizing waste and optimizing material
regulatory compliance need to be addressed to ensure the usage. This can result in cost savings and reduced
long-term economic sustainability of this technology. environmental impact, particularly when working with
C. Social Sustainability expensive or scarce materials.
The social dimension of sustainability encompasses the 4. Customization and Personalization: This technology is
impacts of technology on individuals and communities, ideal for producing customized and personalized
which should not be underestimated. Multi-material 3D products. It allows for the incorporation of various
printing carries various positive social implications [2]: materials to meet specific user requirements, such as
medical implants tailored to an individual's anatomy or
personalized consumer products.
Firstly, it offers consumers highly customized products
tailored to their specific needs and preferences. This enhances 5. Complex Geometries: Multi-material 3D printing can
user experience and satisfaction, aligning with the principles produce objects with intricate and complex geometries
of social sustainability. In the medical field, multi-material that would be challenging or impossible to manufacture
3D printing holds immense promise for improving using traditional methods. This capability is particularly
healthcare. It enables the fabrication of advanced prosthetics, valuable in industries like aerospace and healthcare,
personalized implants, and innovative drug delivery systems, where lightweight and complex structures are essential.
ultimately enhancing the quality of life for patients. 6. Prototyping and Rapid Iteration: The ability to use
Furthermore, accessible 3D printing technology in multiple materials in a single print makes multi-material
educational institutions and communities can foster 3D printing a powerful tool for rapid prototyping and
creativity, innovation, and STEM (Science, Technology, iterative design. Designers can quickly test different
Engineering, and Mathematics) education, contributing material combinations and geometries, accelerating the
positively to social sustainability. [11] product development cycle.
Disadvantages of Multi-Material 3D Printing [4]:
Additionally, the growth of multi-material 3D printing can
create job opportunities in various sectors, including design, 1. Limited Material Selection: While the range of available
engineering, and maintenance, thereby addressing social 3D printing materials has expanded in recent years, multi-
sustainability through employment generation. However, it is material 3D printing still has limitations compared to
essential to acknowledge the potential negative social traditional manufacturing processes. Not all materials are
impacts of multi-material 3D printing. These include compatible with multi-material printers, and material
concerns about job displacement due to automation, the choices can be restricted.
existence of a digital divide in access to advanced technology, 2. Technical Challenges: Multi-material 3D printing is a
and ethical dilemmas related to the misuse of 3D printing complex process that involves precise material deposition
technology for purposes such as producing firearms or and coordination. Achieving consistent and reliable
counterfeit products. results can be technically challenging and may require
specialized equipment and expertise.
IV. ADVANTAGES AND DISADVANTAGES 3. Longer Print Times: Printing with multiple materials often
takes more time than single-material printing due to the
The use of various materials concurrently or sequentially need for material switches and coordination between
during the 3D printing process allows for the fabrication of materials. This can result in longer production cycles,
intricate, multi-component items. Due to its distinctive which may not be suitable for high-volume
qualities, this method has attracted considerable interest and manufacturing.
has been adopted in numerous sectors. However, it has
benefits and drawbacks just like any other technology. 4. Post-Processing Requirements: While multi-material 3D
printing can reduce assembly requirements, some post-
The advantages of multi-material 3D Printing are [5]: processing may still be necessary to refine the surface
1. Enhanced Functionality: The capacity to produce items finish or remove support structures. This can add time and
with enhanced functionality is one of the most important complexity to the production process.
benefits of multi-material 3D printing. Designers can 5. Cost: Multi-material 3D printers tend to be more
create components with distinctive qualities that would be expensive than single-material printers, both in terms of
difficult to obtain using conventional manufacturing initial investment and ongoing operational costs.
techniques by combining various materials with varied Additionally, the cost of materials can be higher for
attributes, such as strength, flexibility, and conductivity. specialized multi-material filaments or resins.
2. Reduced Assembly Requirements: Traditional 6. Complexity and Maintenance: Multi-material 3D printers
manufacturing often involves assembling multiple parts are often more complex machines, which can require
to create a finished product, which can be time- more maintenance and troubleshooting. This complexity
consuming and costly. Multi-material 3D printing allows may also make them less accessible to smaller businesses
for the creation of integrated components, reducing the or individuals.

7
 V. APPLICATIONS energy storage devices. A schematic of the energy harvester
The global industry and scientific communities greatly benefit device using metal–plastic MMs is illustrated in Fig. 5.
from new studies and technical innovations focused on
increasing multifunctionality in many applications made
possible by MM products. When compared to conventional
structures, the ability to create customized MM structures
using 3D printing technology allowed for specific material
selections and enhanced different desired component
properties. Numerous high-tech engineering disciplines,
particularly the aerospace industry, have benefited greatly
from the development of MMAM. The importance of
developing and utilizing multi-material components has also
been acknowledged since they help in the development of
lightweight designs and allow for tooling testing in space. For
the production of MM components used in any aircraft or
space mission, the choice of material, such as metal powder,
ceramics, polymer, and reinforced composites, as well as its
performance, is essential. Additionally, MMAM-related
technology developments have led to significant
improvements in medicine. With the use of biodegradable
polymers for cell encapsulation and drug delivery systems,
significant progress has been made in the production of tissue Figure 5. Energy harvester device
engineering structures for sensitive human body parts using
bio-inspired design principles. B. Multi-material bioprinting
The phrase "bio-printing" refers to the "material transfer
process" that uses cells, biological molecules, and chemicals
A. MMAM of electronic components to create biological materials including cells, tissues, and
Electrically different materials, such as conductors, organs. The development of a 3D or 4D bioprinting
semiconductors, and dielectrics, have been integrated with the engineering branch is very helpful due to an increase in organ
help of MMAM. These materials are crucial parts in the direct transplants but the restricted supply of organs for transplant,
manufacturing of three-dimensional electronic devices. including the current limitations of tissue engineering. The
MMAM can be used to create a variety of electronic parts, physical and chemical properties of objects produced by
including pressure sensors, smart sensor integration, and single-material 3D bioprinting are often not very diverse. To
microelectromechanical systems. To facilitate human- create a 3D printable composite with excellent performance,
occupied tasks that would be unachievable without the aid of such as ideal mechanical properties, desired biocompatibility,
3D printing technology due to the labour-intensive assembly improved biomimicking of tissue structures, and appropriate
process, Hainsworth et al. designed a malleable soft-robot fidelity, a rapidly growing interest in the modification and
actuator with embedded sensors and integrated it into a robotic diversification of generic printing materials by combining
arm's end effector grabbing system. Many MMAM processes, them with other materials exhibiting special properties is
such as FDM, which can generate embedded sensors, and encouraging the application of MMAM in the bioprinting
multi-material extrusion technology, which can fabricate field. The goal of MM bio-printing is to eliminate the
pressure sensors, can use various materials to create electrical problems associated with single-material and replicate in
devices or components. [3] scaffolds the complex architecture of living tissue and organs.
With the integration of many features into a single project,
Single-layer deposition is a conventional method for
multi-material 3D bioprinting creates usable products with
fabricating electronic components, but it has various
essential durability and performance. [7]
limitations that make it unsuitable for high-performance
electronic applications. However, the ability to construct
multilayered capacitors and inductors removes the prior
design constraint and opens up new opportunities for high- C. Soft robotics
performance electronics. Multilayered circuit fabrication is Instead of employing the rigid, hard joints seen in traditional
subject to several limitations because there are few robots, soft robotics uses flexible, pliable materials. They offer
possibilities for printing procedures, even though multilayered a multitude of applications in the bio-robotics, medical,
MM avoids numerous often required steps in conventional industrial, and aerospace industries due to their higher degrees
manufacturing. A specific study has successfully shown how of freedom. The creation of flexible robots with movements
to fabricate several kinds of fully printed multilayered circuits that mirror those of living things is the main goal of soft
using AM techniques. The term "active components" refers to robotics. The development of soft robotics and actuators in
a group of basic logic circuit building blocks that are numerous industries has a lot of potential thanks to MMAM
frequently used in high-end electronics, such as transistors and technology. The recent developments in the 3D printing of
diodes. These parts frequently have multilayered designs and soft materials, such as thermoplastic silicone or polyurethane-
need a variety of materials, including dielectrics, based materials, biologically inspired materials, shape-
semiconductors, and conductors. 3D-printed energy devices memory materials (SMMs), stimulus-response materials, and
are relatively new compared to other electronic components stimuli-responsive materials, make it possible for AM
and devices, and they represent a growing area of research. technologies to be widely used for the development of soft
Energy devices can be categorized into energy harvesting and robots. The main AM procedures for manufacturing soft

8
robots are FFF, direct ink writing, DLP, and SLA. The core of metallic or ceramic elements on a structure made of 3D
a soft robot is its actuation, which is the conversion of energy printed materials. These multi-material systems make use of
into mechanical work. As a result, it affects several variables, post-processing methods including coating, electroless
including the movements made by soft robots and the deposition, sputtering, or atomic layer deposition and don't
necessary manufacturing procedure. Numerous actuation require changing an existing 3D printing system. These
technologies have been created, including hybrid actuation, multi-material systems significantly improve the base
shape-memory materials (SMMs), electroactive polymers material scaffold's features, such as conductivity, super
(EAP), flexible fluidic actuation (FFA), and cable-driven elasticity, biocompatibility, and surface property modulation.
actuation.
VI. FUTURE SCOPE The other kind of multi-material configuration occurs when
two or more materials have three-dimensional architectures
A. Integration of material gradients at different length that are distinct from one another. This contains layers with
scales different materials or layers with different materials arranged
The augmentation and tolerability of material properties, in a random pattern. The most common way to do this kind
including mechanical, thermal, electrical, and multi- of setup is to modify an existing 3D printing method for
functional capabilities, are made possible by the integration single materials and combine it with a mechanical device that
of materials at various length scales (nanoscale and enables switching, mixing, or simultaneous deposition of
macroscale). Nanocomposites are frequently used as a several materials. By layer-by-layer co-depositing various
subsequent phase in additive manufacturing processes that materials, for instance, 3D printing techniques based on
require such multi-material integration. Another crucial jetting or extrusion often require the least amount of system
factor is the noticeable effects on the macroscopic properties adjustment. [6]
via adding only a small quantity of nanoscale reinforcement
C. Design for multi-materials
inclusion, due to the high surface area of the smaller length-
scale material inclusion. This is particularly significant to The use of several materials in additive manufacturing has
additive manufacturing. This is particularly crucial for improved design freedom and brought attention to the need
additive manufacturing because, when a new material that for more effective design processes and tools. The de facto
might not be processable in greater quantity is introduced, the industrial standard for storing design files for additive
processability-property trade-off in multi-material additive manufacturing has been the STL file. The target part's
manufacturing can be reduced by such nanoscale material properties, colour, gradients, or sub-structure, which
reinforcement. As a result, adding material gradients at can be produced using multi-material additive
various length scales throughout a build has made them one manufacturing, are not taken into account by this file format.
of the most promising choices for enhancing material Unlike its predecessor, the STL format, the additive
characteristics and expanding the available material palette, manufacturing file format (AMF) is an open standard
with a reasonable process-property trade-off. (ISO/ASTM 52915:2016) and contains native support for
colour, materials, lattices, and constellations. Even though
this file format seems to be excellent for multi-material
additive manufacturing, it is still not in common use or being
used by the major manufacturers of additive manufacturing.
As of right now, STL formats are still extensively used for
digital design files for multi-material additive manufacturing.
These files are often divided into sub-components based on
various materials for upcoming slice generations and
firmware code generations.

Figure 6. Multi-material light-based additive manufacturing of

embedded carbon nanocomposite structures with multi-material
digital light processing. [2]

B. Hybrid/dissimilar material systems

The co-printing of disparate materials is another dimension
for multi-materials, as opposed to material systems with
different inclusion gradients. Multi-material spatial
arrangements might be more or less complicated, and each
level of complexity necessitates a unique additive
manufacturing strategy and integration technique. Using Figure 7. End effector using PLA and TPU material
conformal joining, several materials are combined to create a
hybrid material at the first level. For instance, printing
metallic components on a copper substrate or deposition of

9
Design approaches and theories for multi-material systems [2] Zheng, X., Williams, C., Spadaccini, C.M. et al. Perspectives on multi-
material additive manufacturing. Journal of Materials Research 36,
with tailorable attributes have been expanding quickly. In the 3549–3557 (2021). https://doi.org/10.1557/s43578-021-00388-y
design for multi-materials, they can be boiled down to three [3] S. Hasanov et al., “Review on Additive Manufacturing of Multi-
major goals: (1) extreme properties; (2) removing the trade- Material Parts: Progress and Challenges,” Journal of Manufacturing
off between mutually exclusive features; and (3) properties and Materials Processing, vol. 6, no. 1, p. 4, Dec. 2021, doi:
that adapt over time (so-called 4D printing). (1) Extremal 10.3390/jmmp6010004. http://dx.doi.org/10.3390/jmmp6010004
qualities previously unattainable by a single material were [4] S. F. Iftekar, A. Aabid, A. Amir, and M. Baig, “Advancements and
Limitations in 3D Printing Materials and Technologies: A Critical
made available by optimizing multi-material distributions in Review,” Polymers, vol. 15, no. 11, p. 2519, May 2023, doi
a complicated topology. These characteristics include 10.3390/polym15112519. http://dx.doi.org/10.3390/polym15112519
extreme thermal conductivity, bulk modulus, super elasticity, [5] Daehoon Han, Howon Lee, "Recent advances in multi-material
acoustic bandgaps, negative and tailorable coefficient of additive manufacturing: methods and applications", Current Opinion in
Chemical Engineering, Volume 28, 2020, Pages 158-166, ISSN 2211-
thermal expansion, and extreme Poisson's ratio under large 3398, https://doi.org/10.1016/j.coche.2020.03.004
deformation. (2) Dual material interphase structures also [6] R. Velu, R. Sathishkumar, and A. Saiyathibrahim, ‘Perspective
offer advantages over trade-offs between mutually exclusive Chapter: Multi-Material in 3D Printing for Engineering Applications’,
features. For instance, compared to composites made of a Advanced Additive Manufacturing. IntechOpen, Jul. 20, 2022. doi:
single material, carbon fibre-reinforced composites have https://doi.org/10.5772/intechopen.102564
higher modulus and strength but also higher brittleness. [7] L.R. Lopes, A.F. Silva, O.S. Carneiro, "Multi-material 3D printing:
The relevance of materials affinity on the boundary interface
performance", Additive Manufacturing, Volume 23, 2018, Pages 45-
VII. CONCLUSION 52, ISSN 2214-8604. https://doi.org/10.1016/j.addma.2018.06.027
In conclusion, the field of additive manufacturing has been [8] Guo Liang Goh, Wai Yee Yeong, Jannick Altherr, Jingyuan Tan,
completely transformed by the development of multi-material Domenico Campolo, "3D printing of soft sensors for soft gripper
3D printing. This essay has investigated this cutting-edge applications", Materials Today: Proceedings, Volume 70, 2022, Pages
224-229. https://doi.org/10.1016/j.matpr.2022.09.025
technology in-depth, looking at its numerous techniques,
sustainability considerations, benefits, disadvantages, [9] A. García-Collado, J.M. Blanco, Munish Kumar Gupta, R. Dorado-
Vicente, "Advances in polymers based Multi-Material Additive-
applications, and final reflections. It is clear from our analysis Manufacturing Techniques: State-of-art review on properties and
that multi-material 3D printing has enormous potential but applications", Additive Manufacturing, Volume 50, 2022, 102577,
also poses several difficulties that call for additional study and ISSN 2214-8604. https://doi.org/10.1016/j.addma.2021.102577
improvement. [10] U. Shaukat, E. Rossegger, and S. Schlögl, “A Review of Multi-Material
3D Printing of Functional Materials via Vat Photopolymerization,”
The many methods used in multi-material 3D printing, from Polymers, vol. 14, no. 12, p. 2449, Jun. 2022, doi:
inkjet-based tactics to extrusion-based processes, were a key https://doi.org/10.3390/polym14122449
component of this inquiry. Each approach has particular [11] Enrique Javier Carrasco-Correa, Ernesto Francisco Simó-Alfonso, José
benefits and drawbacks that add to the field's diverse abilities. Manuel Herrero-Martínez, Manuel Miró, "The emerging role of 3D
printing in the fabrication of detection systems", TrAC Trends in
To fully utilize the capabilities of multi-material 3D printing, Analytical Chemistry, Volume 136, 2021, 116177, ISSN 0165-9936,
it is essential to comprehend the subtleties of these techniques. https://doi.org/10.1016/j.trac.2020.116177
This study clarifies how multi-material 3D printing fits with
sustainable practices, which are a crucial concern in
contemporary production. It draws attention to the potential
for recycling in multi-material printing processes and its
contribution to lowering material waste and raising energy
efficiency. These factors have a bigger role in determining
how manufacturing will develop in the future as
environmental awareness continues to rise.
This study also notes that there are difficulties, such as post-
processing needs and problems with material compatibility.
The current level of multi-material printing is also constrained
by resolution and speed limits, providing areas for additional
research and improvement. Multi-material 3D printing is
essentially a new frontier in technology that has the potential
to revolutionize production, sustainability, and product
design.

VIII. REFERENCES

[1] Aamer Nazir, Ozkan Gokcekaya, Kazi Md Masum Billah, Onur

Ertugrul, Jingchao Jiang, Jiayu Sun, Sajjad Hussain, “Multi-material
additive manufacturing: A systematic review of design, properties,
applications, challenges, and 3D printing of materials and cellular
metamaterials”, in Materials & Design, Volume 226, 2023, 111661,
ISSN 0264-1275. https://doi.org/10.1016/j.matdes.2023.111661

10