MULTI-MATERIAL ADDITIVE MANUFACTURING FOR INTEGRATED ELECTROMECHANICAL SYSTEMS

Abstract

Multi-material additive manufacturing (MMAM) has emerged as a disruptive technological advancement that redefines the fabrication of integrated electromechanical systems by enabling the co-deposition of dissimilar materials—such as conductors, insulators, structural polymers, and elastomers—within a single, layer-by-layer printing process. Unlike conventional manufacturing techniques that require multiple fabrication and assembly stages to integrate mechanical and electrical components, MMAM allows for the simultaneous realization of structural integrity and functional performance in compact, lightweight, and geometrically complex devices. The objective of this study is to conduct a comprehensive meta-analysis of empirical research on MMAM, systematically evaluating its capabilities, performance metrics, and application outcomes across domains such as aerospace, biomedical engineering, soft robotics, and consumer electronics. Following PRISMA guidelines, a total of 122 peer-reviewed studies published between 2010 and 2023 were selected from major academic databases. Data were extracted on material types, fabrication methods, interface strategies, application domains, and quantitative performance outcomes related to mechanical strength, conductivity, interfacial adhesion, and system-level reliability. Effect sizes were computed using a random-effects model, and heterogeneity and publication bias were statistically assessed. The meta-analysis revealed substantial improvements in tensile and shear strength, often ranging between 15% and 35%, when using reinforced or hybrid MMAM techniques compared to monomaterial counterparts. Interface stability was enhanced through the use of micro-patterned geometries, graded material transitions, and in-situ curing strategies, which significantly reduced delamination and warping. Application-specific findings showed that MMAM enabled the fabrication of prosthetics with embedded EMG sensors, soft robotic actuators with integrated strain gauges, and structural aerospace components with in-built diagnostic sensors—all within single uninterrupted manufacturing cycles. Furthermore, lifecycle analysis confirmed higher fatigue resistance, sensor stability, and environmental resilience across embedded systems, supporting MMAM’s viability for deployment in demanding operational environments. The results conclusively position MMAM as a scalable and multifunctional fabrication platform capable of producing integrated electromechanical systems with enhanced performance, reduced complexity, and unprecedented design freedom. This study provides critical insights into MMAM’s current state-of-the-art and its broad potential to transform both industrial manufacturing and functional prototyping in high-performance sectors.