Additive Manufacturing of Metal Materials for Construction Engineering: An Overview on Technologies and Applications

Additive manufacturing, better known as 3D printing, is an innovative manufacturing technique which allows the production of parts, with complex and challenging shapes, layer by layer mainly through melting powder particles (metallic, polymeric, or composite) or extruding material in the form of wire, depending on the specific technique. Three-dimensional printing is already widely employed in several sectors, especially aerospace and automotive, although its large-scale use still requires the gain of know-how and to overcome certain limitations related to the production process and high costs. In particular, this innovative technology aims to overtake some of the shortcomings of conventional production methods and to obtain many additional advantages, such as reduction in material consumption and waste production, high level of customisation and automation, environmental sustainability, great design freedom, and reduction in stockpiles. This article aims to give a detailed review of the state of scientific research and progress in the industrial field of metal additive manufacturing, with a detailed view to its potential use in civil engineering and construction. After a comprehensive overview of the current most adopted additive manufacturing techniques, the fundamental printing process parameters to achieve successful results in terms of quality, precision, and strength are debated. Then, the already existing applications of metal 3D printing in the field of construction and civil engineering are widely discussed. Moreover, the strategic potentiality of the use of additive manufacturing both combined with topological optimisation and for the eventual repair of existing structures is presented. It can be stated that the discussed findings led us to conclude that the use of metal additive manufacturing in the building sector is very promising because of the several benefits that this technology is able to offer.