This chapter gives a brief review of the development of additive manufacturing (AM) and the appeal of different of different AM methods.

This chapter reviews some of the differences between powder metallurgy and additive manufacturing and explains how they influence the microstructure and properties of various alloys and the formation of defects in manufactured parts.

This chapter discusses the advantages and limitations of 3D printing technology for the production of batteries and supercapacitors. It explains how 3D printing methods facilitate the build of microdevices with hierarchical nanoarchitectures and controlled microstructure. It also reviews recent progress in fabricating electrodes and electrolytes using 3D-printed functional materials.

This chapter assesses the state of 3D printing among automakers, medical device manufacturers, and construction companies.

The conversion of feedstock into a shape involves the application of heat and pressure, and possibly solvents. This chapter discusses the operating principle, advantages, limitations, and applications of such shaping processes, namely additive manufacturing, cold isostatic pressing, die compaction, extrusion, injection molding, slip casting, slurry processes, and tape casting. Information on equipment setup, requirements, and the various factors influencing these processes are described. In addition, the chapter provides information on novel approaches and processing costs applicable to these shaping processes.

This chapter is intended to identify materials, processes, and designs that will lead to great advances in powder-binder forming technologies. It discusses some of the structures obtained through these advances in powder-binder technologies such as binder jetting and extrusion-based additive manufacturing, including bound-metal deposition and fused-filament fabrication: oxidation-resistant high-temperature alloys, anisotropic structures, submicrometer-scale structures, surface hard materials, and artist metallic clays. Some of the advances discussed include the developments in process involving plastics, emulsions, ceramics, and porous structures and foams. Improvements in the design processes have led to the development of functional structures, controlled porosity, and bioinspired structures.

This chapter discusses the application of high-pressure cold spray to the automotive industry field, with special attention to three applications: additive manufacturing, fabrication methods, and protective coatings. Various studies on the automotive application of cold spray are reviewed. The background and purpose of each application are presented and practical cases are discussed.

Cold spray coatings technology has the potential to provide surface enhancement for applications in sectors such as defense and aerospace, oil and gas, power generation, medical, automotive, electronics, and railways. The ability to deposit clean metallic coatings is used in applications requiring corrosion/oxidation protection, erosion/wear protection, additive manufacturing, and fabricating free forms. This chapter discusses the function, advantages, and benefits of some of these applications.

This chapter provides details on powder-binder processing for three materials, namely precipitation-hardened 17-4 PH stainless steel, cemented carbides, and alumina. The types of powders, binders, feedstock, shaping processes, debinding, sintering cycles, compositions, microstructure, distortion, postsintering treatments, and mechanical properties are presented for each. The shaping options include powder-binder approaches such as binder jetting, injection molding, extrusion, slip and slurry casting, centrifugal casting, tape casting, and additive manufacturing. Sintering options are outlined with respect to attaining high final properties.