3D Printing of Polymer-Based Functionally Graded Materials: Recent Developments and Challenges

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Year : 2026 | Volume : 14 | 02 | Page :
    By

    Shaik. Nagoor Baba,

  • S. N. Padhi,

  • Charan Gopi Krishna Kondapalli,

  1. M. Tech Student, Department of Mechanical Engineering, Koneru Laksmaiah Education Foundation, Vaddeswaram, Guntur District, Andhra Pradesh, India
  2. Professor, Department of Mechanical Engineering, Koneru Laksmaiah Education Foundation, Vaddeswaram, Guntur District, Andhra Pradesh, India
  3. M. Tech Student, Department of Mechanical Engineering, Koneru Laksmaiah Education Foundation, Vaddeswaram, Guntur District, Andhra Pradesh, India

Abstract

Additive manufacturing (AM), specifically 3D printing, has become a useful technique for fabricating functionally graded materials (FGMs) because it can facilitate the spatial distribution of materials. Polymer FGMs (P-FGMs) have gained a great deal of interest due to their lightweight, customizable, multifunctional properties.  In comparison to conventional fabrication, 3D printing allows better control of composition and microstructure, which results in materials with controlled mechanical, thermal, and biological properties. This review paper discusses the latest works in 3D printing P-FGMs, both experimental and computational. Different gradation profiles, including linear, exponential, and bio-inspired, have been developed through the use of varied processes, including fused deposition modelling (FDM), stereolithography (SLA) and direct ink writing (DIW). Computational tools such as topology optimization and finite element modelling (FEM) are being more widely used to predict stress distribution and optimize printing conditions for maximum strength, creep resistance and functional capability. Although there have been advancements made in the area, challenges persist in achieving high-resolution gradation, strong interlayer bonding, and reproducibility of properties. The study reviews applications of P-FGMs towards biomedical scaffolds, aerospace parts, and electronic packaging, providing experimental evidence. The review contains insights on emerging areas including multi-material 3D printing, machine learning-driven optimization, and sustainable biopolymer-based FGM. In contrast to previous reviews that focused separately on fabrication or modelling, this paper uniquely integrates both experimental and computational perspectives to present a comprehensive framework for polymer-based FGMs.

Keywords: 3D Printing, Polymer FGMs, Additive Manufacturing, Multi-Material Design, Computational Validation.

How to cite this article:
Shaik. Nagoor Baba, S. N. Padhi, Charan Gopi Krishna Kondapalli. 3D Printing of Polymer-Based Functionally Graded Materials: Recent Developments and Challenges. Journal of Polymer & Composites. 2026; 14(02):-.
How to cite this URL:
Shaik. Nagoor Baba, S. N. Padhi, Charan Gopi Krishna Kondapalli. 3D Printing of Polymer-Based Functionally Graded Materials: Recent Developments and Challenges. Journal of Polymer & Composites. 2026; 14(02):-. Available from: https://journals.stmjournals.com/jopc/article=2026/view=239793


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Ahead of Print Subscription Original Research
Volume 14
02
Received 28/10/2025
Accepted 15/11/2025
Published 07/04/2026
Publication Time 161 Days
38

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