Additive manufacturing (AM) has transformed traditional manufacturing processes, revolutionizing the production of complex, customized, and high-performance components. The role of advanced materials developed specifically for AM technologies is critical to the success of this transformation. This review comprehensively covers advanced material classes such as metal-based alloys, ceramics, high-performance polymers, composite systems, smart materials, and functionally gradient materials (FGMs). The compatibility of each material group with AM processes, its mechanical and functional properties, post-production requirements, and application potential are detailed. Furthermore, the compatibility between material selection processes and manufacturing technologies is comparatively evaluated in terms of application-specific performance outcomes. Supported by recent case studies selected from the literature, this review discusses prominent applications, particularly in the aerospace, biomedical, and automotive sectors. Current challenges such as microstructural control, post-process optimization, environmental sustainability, and multi-material manufacturing are also addressed, and future research areas such as AI-assisted material design and nano-additive systems are highlighted. As a result, the integration of advanced material development and AM processes stands out as the key determinant in the production of functional, durable and sustainable products.

Understanding the finishing behavior of hybrid structures produced by additive manufacturing based on FDM is critically important in systems where phases with different thermal and mechanical properties coexist. In this study, the drilling performance of hybrid structures with a PLA/17-4 PH/PLA layer arrangement was comprehensively investigated in terms of thrust force, moment, surface roughness, temperature variation, vibration behavior, and surface integrity. For this purpose, a total of 16 drilling tests were performed on 56 × 56 × 15 mm hybrid specimens with 100% infill density, in a full factorial configuration, at cutting speeds (V) of 80–170 m/min and feed rates (f) of 0.04–0.16 mm/rev. The middle layer was used in the as-printed green state as a 17-4 PH metal-filled filament containing metal particles and binder, without any debinding or sintering step. The results showed that increasing feed rate increased thrust force, moment, and surface roughness in all layers, whereas increasing cutting speed decreased these values and promoted a more stable drilling regime. The middle 17-4 PH layer exhibited lower surface roughness than the outer PLA layers, while thermal measurements indicated limited variation at the hole entrance and higher temperature accumulation at the hole exit. The most favorable drilling condition within the studied hybrid configuration was obtained at 170 m/min and 0.04 mm/rev, whereas the least favorable condition was obtained at 80 m/min and 0.16 mm/rev. Overall, the combination of high cutting speed and low feed rate provided the most suitable drilling window for the studied hybrid structure. The findings also indicated that surface quality was more strongly associated with cutting load and high-frequency vibration components than with vibration level alone.