Advancing Additive Manufacturing through Deep Learning: A Comprehensive Review of Current Progress and Future Challenges

This paper presents the first comprehensive literature review of deep learning (DL) applications in additive manufacturing (AM). It addresses the need for a thorough analysis in this rapidly growing yet scattered field, aiming to bring together existing knowledge and encourage further development. Our research questions cover three major areas of AM: (i) design for AM, (ii) AM modeling, and (iii) monitoring and control in AM. We use a step-by-step approach following the Preferred Reporting Items for Systematic Reviews and Meta-Analyses (PRISMA) guidelines to select papers from Scopus and Web of Science databases, aligning with our research questions. We include only those papers that implement DL across seven major AM categories - binder jetting, directed energy deposition, material extrusion, material jetting, powder bed fusion, sheet lamination, and vat photopolymerization. Our analysis reveals a trend towards using deep generative models, such as generative adversarial networks, for generative design in AM. It also highlights an increasing effort to incorporate process physics into DL models to improve AM process modeling and reduce data requirements. Additionally, there is growing interest in using 3D point cloud data for AM process monitoring, alongside traditional 1D and 2D formats. Finally, this paper summarizes the current challenges and recommends some of the promising opportunities in this domain for further investigation with a special focus on (i) generalizing DL models for a wide range of geometry types, (ii) managing uncertainties both in AM data and DL models, (iii) overcoming limited, imbalanced, and noisy AM data issues by incorporating deep generative models, and (iv) unveiling the potential of interpretable DL for AM.