A review of fused filament fabrication of metal parts (Metal FFF): Current developments and future challenges

Fused filament fabrication (FFF) is the most widespread and versatile material extrusion (MEX) technique. Although powder-based systems have dominated the metal 3D printing landscape in the past, FFF’s popularity for producing metal parts (“metal FFF”) is growing. Metal FFF starts from a polymer–metal composite feedstock and proceeds through three primary stages, namely shaping (i.e., printing), debinding, and sintering. As critically discussed in the present review, the final quality of metal FFF parts is influenced by the characteristics of the composite feedstock, such as the metal loading, polymer backbone, and presence of additives, as well as by the processing conditions. The literature shows that a diverse array of metals, including steel, copper, titanium, aluminium, nickel, and their alloys, can be successfully used in metal FFF. However, the formulation of appropriate polymer binders represents a hurdle to the adoption of new material systems. Meanwhile, intricate geometries are difficult to fabricate due to FFF-related surface roughness and sintering-induced shrinkage. Nonetheless, the comparison of metal FFF with other common metal AM techniques conducted herein suggests that metal FFF represents a convenient option, especially for prototyping and small-scale production. Whilst providing insights into the functioning mechanisms of metal FFF, the present review offers valuable recommendations, facilitating the broader uptake of metal FFF across various industries.