journal article·2026-08-01Open access

Machine learning-assisted process-structure-property correlation in laser metal additive manufacturing: a critical review

Miao Yu, Lida Zhu, Zhichao Yang, Jinsheng Ning, Pengsheng Xue, Shuhao Wang, Lu Wang, Xipeng Tan

Abstract

Abstract Artificial intelligence provides novel perspectives for laser metal additive manufacturing (LMAM), enhancing precision, efficiency, and structural and process optimization. Machine learning-assisted process–structure–property correlation in additive manufacturing (ML-PSP-AM) presents an effective pathway for structural innovation and performance optimization, leveraging automation and intelligence to address the growing processing demands across industries. This review differs from the existing literature by presenting a multi-scale, PSP-centered analysis of ML applications in LMAM, integrating discussions that span from processing-driven macro-scale formation to meso/micro-scale defect prediction and microstructure–property relationships. By evaluating state-of-the-art ML applications across various AM stages, we identify current limitations, propose targeted strategies, and outline opportunities to improve accuracy, minimize defects, and enhance mechanical properties such as strength and fatigue life. The advancement of ML-assisted AM should focus on breakthroughs from “0 to 1” in application and innovations from “1 to ∞” in algorithms. The realization of ML-PSP-AM represents a transformative yet disruptive integration of manufacturing engineering, artificial intelligence, and materials science, driving significant progress in modern manufacturing technologies.
Source: crossref · Quality: baseline

Research context

OpenAlex topics: Additive Manufacturing Materials and Processes · Machine Learning in Materials Science · Additive Manufacturing and 3D Printing Technologies

SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.

References (100+)

Show source-provided references
1. Robust chemical analysis with graphene chemosensors and machine learning10.1038/s41586-024-08003-w ↗
2. Machine learning enhanced metal 3D printing: high throughput optimization and material transfer extensibility10.1088/2631-7990/adbb96 ↗
3. Machine learning–assisted triboelectric nanogenerator technology for intelligent sports10.1126/sciadv.adz3515 ↗
4. Fully integrated wearable control system for micro/nanorobot navigation10.1088/2631-7990/ada8e5 ↗
5. Building personalized machine learning models using real-time monitoring data to predict idiographic suicidal thoughts10.1038/s44220-024-00335-w ↗
6. Expanding drug targets for 112 chronic diseases using a machine learning-assisted genetic priority score10.1038/s41467-024-53333-y ↗
7. Mapping of machine learning approaches for description, prediction, and causal inference in the social and health sciences10.1126/sciadv.abk1942 ↗
8. A machine learning tool to investigate lithium-ion battery degradation under real automotive conditions10.1016/j.jpowsour.2024.236048 ↗
9. Big data and machine learning in cost estimation: an automotive case study10.1016/j.ijpe.2023.109137 ↗
10. Machine learning-based synthesis of diagnostic algorithms for electromechanical actuators to improve the aerospace flight safety10.1016/j.actaastro.2024.10.054 ↗
11. Machine learning and mixed reality for smart aviation: applications and challenges10.1016/j.jairtraman.2023.102437 ↗
12. Digital twin-driven virtual commissioning for robotic machining enhanced by machine learning10.1016/j.rcim.2024.102908 ↗
13. A review on machine learning in flexible surgical and interventional robots: where we are and where we are going10.1016/j.bspc.2024.106179 ↗
14. A systematic review of design for additive manufacturing of aerospace lattice structures: current trends and future directions10.1016/j.paerosci.2024.101021 ↗
15. Strengthening the mechanical properties of selective laser melting (CoCrNi)94Al3Ti3 medium-entropy alloy by combining heat treatment with ultrasonic shot peening10.1016/j.msea.2025.149471 ↗
16. Directed energy deposition (DED) additive manufacturing: physical characteristics, defects, challenges and applications10.1016/j.mattod.2021.03.020 ↗
17. Challenges and opportunities in the production of magnesium parts by directed energy deposition processes10.1016/j.jma.2024.05.004 ↗
18. Crack-free tungsten coating on ODS plate via a modified laser-based additive technique: offset laser cladding10.1016/j.surfcoat.2023.130285 ↗
19. Additive manufacturing for repairing: from damage identification and modeling to DLD10.1108/RPJ-03-2019-0090 ↗
20. Review on laser directed energy deposited aluminum alloys10.1088/2631-7990/ad16bb ↗
21. Radial bimetallic structures via wire arc directed energy deposition-based additive manufacturing10.1038/s41467-023-39230-w ↗
22. Additive manufacturing of alloys with programmable microstructure and properties10.1038/s41467-023-42326-y ↗
23. Nondiffractive beam shaping for enhanced optothermal control in metal additive manufacturing10.1126/sciadv.abg9358 ↗
24. Increasing the friction and wear performance of AISI 316L under dry, aqueous and oil lubricated sliding conditions with surface textures fabricated by laser-powder bed fusion (L-PBF)10.1016/j.triboint.2024.110135 ↗
25. Recent advances on additive manufacturing of heterogeneous/gradient metallic materials via laser powder bed fusion10.1088/2631-7990/adf69e ↗
26. Hole quality geometrical measurement and surface roughness for α-Phase titanium alloy (α-Ti-6Al-4V) materials by using L-PBF (laser powder bed fusion) orthopedic implant application10.1016/j.measurement.2024.115531 ↗
27. In situ monitoring and innovative feature fusion neural network for enhanced laser-directed energy deposition track geometry prediction and control10.1109/TIM.2024.3406808 ↗
28. Machine learning based track height prediction for complex tool paths in direct metal deposition10.1016/j.cirp.2022.03.032 ↗
29. A multi-scale convolutional neural network for autonomous anomaly detection and classification in a laser powder bed fusion additive manufacturing process10.1016/j.addma.2018.09.034 ↗
30. Forecasting of process parameters using machine learning techniques for wire arc additive manufacturing process10.1016/j.matpr.2022.12.081 ↗
31. Multi-objective robust parameter optimization using the extended and weighted k-means (EWK-means) clustering in laser powder bed fusion (LPBF)10.1016/j.eswa.2023.121349 ↗
32. Optimization of process parameters for powder bed fusion additive manufacturing by combination of machine learning and finite element method: a conceptual framework10.1016/j.procir.2017.12.204 ↗
33. A novel porosity prediction framework based on reinforcement learning for process parameter optimization in additive manufacturing10.1016/j.scriptamat.2024.116377 ↗
34. Sensor-integrated data acquisition and machine learning implementation for process control and defect detection in wire arc-based metal additive manufacturing10.1016/j.precisioneng.2025.04.028 ↗
35. Real-time layer height estimation during multi-layer directed energy deposition using domain adaptive neural networks10.1016/j.compind.2023.103882 ↗
36. Understanding and detection of process instabilities in wire arc directed energy deposition additive manufacturing using meltpool imaging and machine learning10.1016/j.matdes.2025.114598 ↗
37. Towards reproducible machine learning-based process monitoring and quality prediction research for additive manufacturing10.1016/j.engappai.2025.112223 ↗
38. Real-time process monitoring and error correction in material extrusion-based additive manufacturing via multi-output machine learning10.1016/j.jmapro.2025.08.025 ↗
39. Recent progress of sensing and machine learning technologies for process monitoring and defects detection in wire arc additive manufacturing10.1016/j.jmapro.2024.07.060 ↗
40. A critical review of process monitoring for laser-based additive manufacturing10.1016/j.aei.2024.102932 ↗
41. Review of online quality control for laser directed energy deposition (LDED) additive manufacturing10.1088/2631-7990/aded4f ↗
42. A multi-purpose robot perception system enabling closed-loop control for zero defect manufacturing in gluing processes of large parts10.1016/j.robot.2024.104778 ↗
43. A microstructure sensitive machine learning-based approach for predicting fatigue life of additively manufactured parts10.1016/j.ijfatigue.2024.108724 ↗
44. A review on physics-informed machine learning for process-structure-property modeling in additive manufacturing10.1016/j.jmapro.2024.11.066 ↗
45. Deep learning-assisted real-time defect detection and closed-loop adjustment for additive manufacturing of continuous fiber-reinforced polymer composites10.1016/j.rcim.2022.102431 ↗
46. Machine learning-based online monitoring and closed-loop controlling for 3D printing of continuous fiber-reinforced composites10.1016/j.amf.2025.200196 ↗
47. Policy needed for additive manufacturing10.1038/nmat4658 ↗
48. Real-time in-process control methods of process parameters for additive manufacturing10.1016/j.jmsy.2024.05.008 ↗
49. Effects of the solution and first aging treatment applied to as-built and post-HIP CM247 produced via laser powder bed fusion (LPBF)10.1016/j.jallcom.2022.164213 ↗
50. Deep learning object detection for optical monitoring of spatters in L-PBF10.1016/j.jmatprotec.2023.118063 ↗
51. On the varieties of build features during multi-layer laser directed energy deposition10.1016/j.addma.2020.101491 ↗
52. Geometrical and crystal plasticity modelling: towards the establishment of a process-structure-property relationship for additively manufactured 316L struts10.1016/j.euromechsol.2023.105115 ↗
53. Strong and ductile titanium–oxygen–iron alloys by additive manufacturing10.1038/s41586-023-05952-6 ↗
54. Highly controllable additive manufacturing of heterostructured nickel-based composites10.1016/j.ijmachtools.2023.104112 ↗
55. Mechanism for feature learning in neural networks and backpropagation-free machine learning models10.1126/science.adi5639 ↗
56. Towards the next generation of machine learning models in additive manufacturing: a review of process dependent material evolution10.1016/j.pmatsci.2023.101102 ↗
57. Unraveling process-microstructure-property correlations in powder-bed fusion additive manufacturing through information-rich surface features with deep learning10.1016/j.jmatprotec.2022.117804 ↗
58. Machine learning in additive manufacturing: state-of-the-art and perspectives10.1016/j.addma.2020.101538 ↗
59. Metallurgy, mechanistic models and machine learning in metal printing10.1038/s41578-020-00236-1 ↗
60. Explainable machine learning for understanding and predicting geometry and defect types in Fe-Ni alloys fabricated by laser metal deposition additive manufacturing10.1016/j.jmrt.2022.11.137 ↗
61. Predicting meltpool depth and primary dendritic arm spacing in laser powder bed fusion additive manufacturing using physics-based machine learning10.1016/j.matdes.2023.112540 ↗
62. Invited review: machine learning for materials developments in metals additive manufacturing10.1016/j.addma.2020.101641 ↗
63. Machine learning algorithms for defect detection in metal laser-based additive manufacturing: a review10.1016/j.jmapro.2021.12.061 ↗
64. Perspectives of using machine learning in laser powder bed fusion for metal additive manufacturing10.1080/17452759.2021.1944229 ↗
65. Research and application of machine learning for additive manufacturing10.1016/j.addma.2022.102691 ↗
66. Material-structure-performance integrated laser-metal additive manufacturing10.1126/science.abg1487 ↗
67. Protection mechanisms of the iron-plated armor of a deep-sea hydrothermal vent gastropod10.1073/pnas.0912988107 ↗
68. Design and printing of proprioceptive three-dimensional architected robotic metamaterials10.1126/science.abn0090 ↗
69. Influence of particle size distribution and morphology on the properties of the powder feedstock as well as of AlSi10Mg parts produced by laser powder bed fusion (LPBF)10.1016/j.addma.2020.101286 ↗
70. Powder-size driven facile microstructure control in powder-fusion metal additive manufacturing processes10.1038/s41467-024-47257-w ↗
71. Surface texture measurement for additive manufacturing10.1088/2051-672X/3/2/024002 ↗
72. Comprehensive review: advancements in modeling geometrical and mechanical characteristics of laser powder bed fusion process10.1016/j.optlastec.2024.111480 ↗
73. Anomaly detection and classification in a laser powder bed additive manufacturing process using a trained computer vision algorithm10.1016/j.addma.2017.11.009 ↗
74. Layer-wise anomaly detection and classification for powder bed additive manufacturing processes: a machine-agnostic algorithm for real-time pixel-wise semantic segmentation10.1016/j.addma.2020.101453 ↗
75. Monitoring of the powder bed quality in metal additive manufacturing using deep transfer learning10.1016/j.matdes.2022.111029 ↗
76. Deep learning for in-situ powder stream fault detection in directed energy deposition process10.1016/j.jmsy.2022.01.013 ↗
77. Recent progress in high-entropy alloys for laser powder bed fusion: design, processing, microstructure, and performance10.1016/j.mser.2024.100834 ↗
78. Defect detection in selective laser melting technology by acoustic signals with deep belief networks10.1007/s00170-018-1728-0 ↗
79. Prediction of melt pool shape in additive manufacturing based on machine learning methods10.1016/j.optlastec.2022.108964 ↗
80. In-situ capture of melt pool signature in selective laser melting using U-Net-based convolutional neural network10.1016/j.jmapro.2021.05.052 ↗
81. Melt pool temperature measurement and monitoring during laser powder bed fusion based additive manufacturing via single-camera two-wavelength imaging pyrometry (STWIP)10.1016/j.jmapro.2022.04.058 ↗
82. A virtual sensing approach for monitoring melt-pool dimensions using high speed coaxial imaging during laser powder bed fusion of metals10.1016/j.addma.2021.101923 ↗
83. Motion feature based melt pool monitoring for selective laser melting process10.1016/j.jmatprotec.2022.117523 ↗
84. Track geometry prediction for Laser Metal Deposition based on on-line artificial vision and deep neural networks10.1016/j.rcim.2022.102445 ↗
85. In-situ multi-eye monitoring of melt pool temperature field in laser additive manufacturing by light field camera10.1016/j.addma.2025.104747 ↗
86. In-situ process monitoring and adaptive quality enhancement in laser additive manufacturing: a critical review10.1016/j.jmsy.2024.04.013 ↗
87. Physical twin of an industrial quad-laser powder bed fusion machine for high-speed multi-modal sensing measurements10.1016/j.matdes.2025.113767 ↗
88. Using machine learning to identify in-situ melt pool signatures indicative of flaw formation in a laser powder bed fusion additive manufacturing process10.1016/j.addma.2018.11.010 ↗
89. In situ monitoring of selective laser melting using plume and spatter signatures by deep belief networks10.1016/j.isatra.2018.07.021 ↗
90. Extraction and evaluation of melt pool, plume and spatter information for powder-bed fusion AM process monitoring10.1016/j.matdes.2018.07.002 ↗
91. Powder-bed fusion process monitoring by machine vision with hybrid convolutional neural networks10.1109/TII.2019.2956078 ↗
92. Heterogeneous sensing and scientific machine learning for quality assurance in laser powder bed fusion—A single-track study10.1016/j.addma.2020.101659 ↗
93. Process mapping and anomaly detection in laser wire directed energy deposition additive manufacturing using in-situ imaging and process-aware machine learning10.1016/j.matdes.2024.113281 ↗
94. Infrared thermographic imaging based real-time layer height estimation during directed energy deposition10.1016/j.optlaseng.2023.107661 ↗
95. Parameter automatic optimization strategy for laser powder bed fusion using neural network infrared radiation intensity prediction model10.1016/j.addma.2024.104373 ↗
96. Rapid surface defect identification for additive manufacturing with in-situ point cloud processing and machine learning10.1080/17452759.2020.1832695 ↗
97. A novel data-driven framework for enhancing the consistency of deposition contours and mechanical properties in metal additive manufacturing10.1016/j.compind.2024.104154 ↗
98. Damage-tolerant architected materials inspired by crystal microstructure10.1038/s41586-018-0850-3 ↗
99. Machine learning assisted investigation of defect influence on the mechanical properties of additively manufactured architected materials10.1016/j.ijmecsci.2022.107190 ↗
100. Deep learning-enabled design for tailored mechanical properties of SLM-manufactured metallic lattice structures10.1016/j.engappai.2023.107685 ↗