A comprehensive review on sustainable cold spray additive manufacturing: State of the art, challenges and future challenges

Integration of additive manufacturing (AM) with Cold spray process is the latest solid-state supersonic deposition method that has gained significant attention of future manufacturing industry owning to its acceptability for mass production, fabrication, and restoration of typical engineering components. Cold spray additive manufacturing (CSAM) can build 3D components and this technique has the potential to change the future of the manufacturing world with remarkable sustainable benefits. This review sums up the research on state-of-the-art and identified key challenges for deploying a CSAM as a repairing, restoration and sustainable fabrication process in the future manufacturing industry. The benefits of CSAM for sustainable manufacturing have been discussed regarding the environmental concerns, and optimized product structures and designs. The outcome of the current study indicates that challenges associated with CSAM can be overcome with careful planning and manufacturing strategies. It also presents the recommended future research directions for CSAM's implementation as an established viable advanced AM process.