Tools and procedures are modified to control process variables, enrich microstructure development, and minimize faults, having recognized metal parts as the central focus of change for additive manufacturing. In particular, altering parameters for residual stress and porosity facilitated fatigues and strength augmentations. Real-time monitoring and modification capabilities ensure a consistent and high-quality production process. Furthermore, combining the additive technique with suitable post-processing techniques fine-tunes microstructure as well as the mechanical behavior, leading metal parts to meet, and in some cases, exceed conventional production standards.

Design optimization and 3D printing serve as two foundational pillars advancing the development of modern composite materials. Recent advancements in 3D printing technologies have significantly enhanced composite quality and expanded the range of printable materials. Design optimization plays a pivotal role in guiding 3D printing to produce composites with exceptional mechanical properties and diverse functionality. Conversely, 3D printing presents enriched challenges that drive the continuous development of advanced design methodologies. Future research should focus on overcoming current limitations, such as improving the mechanical performance and scalability of 3D-printed composites, incorporating adaptable multifunctionality, and advancing theoretical modeling frameworks. By addressing these needs, the field of composite 3D printing can evolve toward realizing its full potential in both industrial and research applications, which paves the way for groundbreaking materials and scalable manufacturing processes.