Wire Arc Additive Manufacturing (WAAM) has gained attention as a metal additive manufacturing process producing complex large-scale components with high deposition rates and lower costs. Cold Metal Transfer (CMT) offers reduced heat input and enhanced control of metal transfer, making it suitable for aluminium. This review analyses CMT-based WAAM with a focus on Al–Si alloys, providing a synthesis for this material system and establishing a structured comparison of representative studies on process fundamentals, arc mode variants, and key processing parameters. The influence of electrical and kinematic parameters and thermal management on process and geometrical stability, microstructural evolution, defect formation, and mechanical behaviour is discussed. Process behaviour is governed by the temporal distribution of heat input within the CMT cycle and thermal history. Control of heat input can reduce porosity, microstructural heterogeneity, and geometric instability, while advanced CMT modes can improve process stability and material efficiency under appropriate process configurations. Mechanical performance depends on the interaction between process parameters, microstructure, and defects, leading to variability and anisotropy. Despite progress, challenges related to process repeatability, narrow processing windows, defect susceptibility, and predictive capability remain. Future research should focus on parameter optimization, integrated modelling, real-time control, and WAAM-specific alloys to enable reliable industrial implementation.

Additive manufacturing via Fused Filament Fabrication (FFF) has enabled the development of functional components with customized mechanical properties. In this context, the use of polymers with flame-retardant additives offers an ideal solution for sectors such as aerospace, where fire resistance is a top priority. However, the tribological properties of these materials have not yet been sufficiently studied, despite their relevance in applications subjected to friction or wear. This study analyzes the tribological behavior of parts manufactured using PETG (Polyethylene Terephthalate Glycol) and flame-retardant PETG (PETG FP) through dry condition Ball-on-Disk tests. The influence of manufacturing parameters such as extrusion temperature and layer height on the coefficient of friction (CoF), surface wear, and roughness is investigated. The results show that PETG FP exhibits an increased CoF compared to conventional PETG, although it demonstrates more stable behavior at elevated temperatures. Statistical analysis via ANOVA reveals that material type and layer height significantly affect tribological properties, while temperature plays a secondary role. This study provides key insights for the selection of polymeric materials in environments with critical functional demands.