Design innovations and high-value-added industrial deployments of additively manufactured advanced aluminum-based materials

High-performance Al-based components with structural-functional integration are essential in modern industry, spanning lightweight designs, energy-efficient systems, and sustainable engineering solutions. In recent years, additive manufacturing (AM) of Al alloys and Al matrix composites (AMCs) has gained significant attraction in advanced engineering due to its potential for high performance and near-net-shape fabrication. Substantial scientific and commercial progress has yielded new AM-suitable advanced alloys and AMCs. This paper provides a dedicated review focusing on recent advances in advanced Al-based materials, particularly their material design strategies and high-value-added applications. This review first outlines Al-based materials and their AM opportunities, then comprehensively surveys recent progress in developing AMed Al alloys, including high-performance Al-Si alloys by processing control, modified wrought Al alloys and tailored Al alloys for AM. Furthermore, recent advances in AM of ceramic-particle-reinforced AMCs have been highlighted, emphasizing the pivotal role of reinforcements in enhancing printability and their influence on microstructural, mechanical, and functional characteristics. Industrial applications of AMed Al-based structures in high-end products are also presented. The review provides state-of-the-art knowledge on developing and applying high-performance Al-based materials by AM and discusses current challenges and future opportunities for advancing AM of these materials.