多材料激光粉末床熔融增材制造与创新设计研究 (特邀)

Significance Multi-material laser powder bed fusion (MM- LPBF) is emerging as a transformative route for manufacturing high-performance metallic components that must satisfy conflicting property demands within a single, integrated geometry, such as concurrently achieving high- temperature strength and thermal conduction, lightweight load-bearing and local wear resistance, or biocompatibility and mechanical compatibility. Conventional joining and assembly routes struggle to deliver such spatially programmable property distributions when complex 3D shapes, internal channels, or graded transitions are required. Although existing reviews have provided abundant case studies on specific processing issues, a system-level integrated design framework that unifies material selection, structural configuration, and performance expectations remains underdeveloped. A design-driven manufacturing perspective is therefore needed to proactively avoid process bottlenecks and maximize component performance benefits, rather than relying primarily on trial-and-error design-for-manufacturing. This review is organized around design-driven manufacturing (DDM). After introducing the enabling powder delivery and powder recovery systems for multi-material fabrication and analyzing the interfacial scientific issues that govern dissimilar-metal integrity, four design paradigms are proposed to construct a cross-scale methodology that links interfacial science, process ‒ structure ‒ property relations, and application-oriented design decisions into an actionable framework. Based on this framework, representative applications in aerospace, biomedical engineering, and other domains are summarized, and future challenges are discussed, including digital twins, machine learning, and process standardization, among others. Progress First, the enabling hardware and process foundation that makes spatial composition control feasible is reviewed, including powder delivery and powder recovery. Mainstream and emerging multi-material spreading concepts are comparatively reviewed, including blade-based spreading, ultrasonic vibration-assisted feeding, electrophotographic selective deposition, and hybrid strategies. State-of-the-art powder recovery and cleaning approaches are further synthesized, ranging from mechanical sweeping to vacuum suction and property-difference-based separation, with emphasis on suppressing cross-contamination and improving powder circularity. Systems-level coupling between delivery and recovery is highlighted, indicating that coordinated multi-technology integration is essential for robust and scalable MM- LPBF. Second, the core scientific questions governing dissimilar-metal integrity are consolidated, focusing on interfacial metallurgical reactions and their mechanisms, while also clarifying the mechanical-property consequences and the leading interface-regulation strategies. For interfacial reactions, interface quality is shown to be governed not only by nominal alloy pairing, but also by melt-pool convection and mixing, repeated remelting ‒ resolidification cycles, and local non- equilibrium solidification behavior. Representative analyses reveal that solidification-path evolution can amplify hot-cracking susceptibility, and that brittle intermetallic compound (IMC) formation can become a dominant cracking trigger. Reaction-layer evolution is interpreted from both thermodynamic driving forces and diffusion kinetics, and multi-layered IMC architectures are illustrated as being governed by wetting, local dissolution, solute segregation, and competitive phase formation. In addition, thermophysical mismatches, including thermal conductivity, melting-point disparity, and thermal expansion differences, are explained in relation to melt-pool stability and defect modes such as lack-of-fusion, poor wetting, warpage, and embrittlement. Dispersed observations are reorganized into a unified comparison table, where interface mechanisms are classified into major types and linked to key reactions, quality indicators, and process-control levers. For mechanical behavior, it is summarized that well-bonded interfaces typically exhibit hardness gradients, while localized hardening may arise from grain refinement or hard IMC phases. Tensile responses depend on interface orientation, anisotropy, and other influencing factors; failure can shift from the weaker base material to the interface region when brittle layers are present. For interface regulation, three reviewed directions are emphasized: composition-gradient transitions that buffer property discontinuities, intermediate interlayers that mitigate immiscibility and suppress harmful reactions while improving wetting and diffusion pathways, and interface interlocking architectures inspired by hierarchical or bioinspired geometries to increase contact area, redistribute stress, and enhance shear/bending resistance. Emerging trends toward generalized parameter development and data-driven mapping for graded regions are also noted to reduce trial-and-error tuning. Third, based on the above scientific basis, the DDM-driven design methodology is presented as four complementary paradigms that collectively span micro-to-system scales. (i) Composition-driven design treats the transition zone as a computable metallurgical system and leverages ICME/CALPHAD with non-equilibrium solidification analysis to predict phase risks and plan composition pathways that avoid brittle regions, then converts the pathway into executable mixing/deposition instructions. (ii) Performance-driven design focuses on macro-scale optimal material placement using multi-material topology optimization, enabling performance/cost co-optimization and introducing process-aware constraints such as interface reliability metrics so that optimal solutions remain manufacturable and robust. (iii) Structure-driven design programs emergent properties through meso-/micro-architectures, including bioinspired layered motifs and multi-material metamaterials, where geometry and material assignment jointly control stiffness, toughness, Poisson's ratio, thermal expansion, and energy absorption beyond rule-of-mixtures limits. (iv) Function-driven design elevates printed parts into integrated multi-physics systems by embedding sensing/actuation or co-designing channels, electronics, and protective structures under coupled thermal‒mechanical‒electrical constraints, enabling lifecycle coupling between physical components and their digital representations. Together, these paradigms constitute the core of the DDM-oriented cross-scale methodology, translating design intent into material‒structure allocation, interface regulation, and process strategies for predictable performance realization. Fourth, application landscapes are reviewed to demonstrate how the DDM-oriented framework translates into engineering value. Representative MM-LPBF implementations in aerospace leverage graded transitions and multi-material layouts for thermal management and high-temperature service; in biomedical devices, multi-material architectures combine mechanical support with bioactive or porous functional layers; and in consumer and creative industries, MM-LPBF enables integrated multi-metal aesthetics and fine-feature customization beyond traditional manufacturing routes. These examples underline the importance of systematic design-to-manufacture integration for multi-material systems. Conclusions and Prospects Reliable MM-LPBF is concluded to require a coupled foundation: (1) coordinated powder delivery and recovery to ensure spatial composition fidelity and minimize contamination; (2) mechanistic understanding of interfacial reactions, defect formation, and their mechanical consequences; and (3) proactive interface regulation via gradients, interlayers, and interlocking architectures. On this basis, the proposed DDM methodology, organized through the four paradigms of composition-, performance-, structure-, and function-driven design, provides a coherent cross-scale roadmap that formalizes how material selection, spatial layout, interfacial control, and process parameters can be co-designed toward predictable performance and system integration. Looking forward, high-impact opportunities lie in digital twins and machine learning. Digital twins are expected to evolve toward multi-material, multi-physics, and process-aware models capable of capturing interfacial reactions, thermophysical coupling, and powder contamination evolution, supported by standardized, high-quality data infrastructures. Machine learning integrated with the digital twin is expected to enable real-time perception, defect-risk prediction, and closed-loop parameter adaptation. In parallel, progress is required in equipment and process standardization, modular system design, generalized parameter-development workflows, reliability of embedded functional interfaces, and sustainable powder reuse rules tailored to multi-material mixtures. Advancing along these directions is expected to accelerate MM-LPBF toward certifiable and scalable industrial deployment, aligned with DDM-oriented design objectives. © 2026 Chinese Laser Press. All rights reserved.