CUSTOMIZATION AND SUSTAINABILITY THROUGH 3D PRINTING: APPLICATIONS FROM AUTOMOTIVE TO CONSUMER PRODUCTS

Marinela COSMA, Horațiu VERMEȘAN

Abstract


This paper provides an overview of Fused Deposition Modeling (FDM), from its first patent to widespread adoption as a core additive manufacturing technology. The working principle, advantages, and limitations are discussed, with emphasis on cost efficiency and design freedom. Common filaments and reinforced materials are reviewed in terms of physical–mechanical properties and applications. Several world-premiere 3D-printed applications are presented, such as the first car, an electric motorbike, and a jet-powered drone. From a sustainability perspective, FDM enables material reuse and waste reduction, achieving savings of up to 70%. Industrial case studies, including automotive (Volkswagen, BMW), military drones (British Navy), medical orthoses (BioNeek), and footwear (MIT–Adidas, Zellerfeld), demonstrate FDM’s expanding role in mass customization across multiple sectors.

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