Laser‐Based Selective Material Processing for Next‐Generation Additive Manufacturing

The connection between laser‐based material processing and additive manufacturing is quite deeply rooted. In fact, the spark that started the field of additive manufacturing is the idea that two intersecting laser beams can selectively solidify a vat of resin. Ever since, laser has been accompanying the field of additive manufacturing, with its repertoire expanded from processing only photopolymer resin to virtually any material, allowing liberating customizability. As a result, additive manufacturing is expected to take an even more prominent role in the global supply chain in years to come. Herein, an overview of laser‐based selective material processing is presented from various aspects: the physics of laser‐material interactions, the materials currently used in additive manufacturing processes, the system configurations that enable laser‐based additive manufacturing, and various functional applications of next‐generation additive manufacturing. Additionally, current challenges and prospects of laser‐based additive manufacturing are discussed. Laser‐based material processing is extensively studied in manufacturing techniques to fabricate functional components with 3D features or intricate patterns. This review provides a comprehensive understanding of four major aspects of laser‐based additive manufacturing: laser sintering physics, materials and methodology for laser processing, and various applications. Furthermore, challenges and perspectives are discussed to explore promising opportunities for laser‐based material processing.