A review on layerless 3D printing: challenges and applications

Abstract

Purpose

This paper aims to provide a full introduction, new classification, comparison and investigation of the challenges as well as applications of layerless 3D printing, which is one of the industry 4.0 pioneers.

Design/methodology/approach

Given the significance and novelty of uniform 3D printing, more than 250 publications were collected and reviewed in an unbiased and clear manner.

Findings

As a result, the majority of uniform parts printed in polymer form are known up to this point. In a novel division for better researchers’ comprehension, uniform printing systems were classified into three categories: oxygen inhibition (OI), liquid lubrication (LL) and photon penetration (PP), and each was thoroughly investigated. Furthermore, these three approaches were evaluated in terms of printing speed, precision and accuracy, manufacturing scale and cost.

Originality/value

The parameters of each approach were compared independently, and then a practical comparison was conducted among these three approaches. Finally, a variety of technologies, opportunities, challenges and advantages of each significant method, as well as a future outlook for layerless rapid prototyping, are presented.

Citation

Moayedi, S., Zamani, J. and Salehi, M. (2025), "A review on layerless 3D printing: challenges and applications", Rapid Prototyping Journal, Vol. 31 No. 2, pp. 409-431. https://doi.org/10.1108/RPJ-03-2024-0145