Additive manufacturing (AM) offers the possibility to produce components in a resource-efficient and environmentally friendly way. AM can also be used to optimise the design of components in mechanical and physical terms. In this way, functionally integrated, lightweight, highly efficient, and innovative components can be manufactured with the help of additive manufacturing in terms of Industry 4.0. Furthermore, requirements in the automotive industry for drivetrain components are increasingly being trimmed in the direction of efficiency and environmental protection. Especially in electromobility, the topic of green efficiency is an essential component. Exhaust emission legislation and driving profiles for evaluating vehicles are becoming increasingly detailed. This offers the potential to apply the advantages of AM to vehicle types such as conventional, utility vehicles, and nonroad mobile machinery (NRMM), independent of the electrical drivetrain technology (hybrid or fully electrical). AM also allows for us to produce optimally adapted components to the respective requirements and use cases. In this review, the intersections of AM and electromobility are illuminated, showing which solutions and visions are already available for the different vehicle types on the market and which solutions are being scientifically researched. Furthermore, the potential and existing deficit of AM in the field of electromobility are shown. Lastly, new and innovative solutions are presented and classified according to their advantages and disadvantages.

Conventional supply chains depend on spare part inventories for rapid failure response. Metal additive manufacturing enables decentralized, on‐demand production, reducing inventory needs. Current research focuses on redesigning spare parts using failure data. Key aspects include lightweight design through generative topology optimization, material substitution, and cost analysis to improve efficiency. Generative design enhances performance while reducing material use and production costs, supporting sustainability. This is especially relevant in industries where weight and material savings improve performance and reduce expenses. This study presents an integrated approach combining material selection, bionic design, and cost estimation in metal additive manufacturing to evaluate decentralized spare part reproduction. Findings show that generative design enables fast, cost‐effective, and sustainable improvements, supporting operational efficiency and environmental goals.

This research provides an extensive and sophisticated analysis of debris produced by micro‐electrical discharge machining processing of Ni‐Ti shape memory alloys and austenitic stainless steel (SS304) using brass electrodes. The research examines how different discharge energy levels controlled by capacitance and voltage affect debris shape and electrode wear and workpiece erosion. The analysis of particle morphology and elemental distribution uses scanning electron microscopy and energy dispersive X‐ray spectroscopy. The research shows that irregular debris forms at low energy levels but higher discharge energies lead to spheroidization through localized melting. The analysis shows that debris composition receives material contributions from both the workpiece and electrode sources. The substantial oxidation levels demonstrate how dielectric decomposition affects the process. The research findings directly affect micro‐fabrication operations that need both high surface quality and precise dimensional control.