Comprehensive explanation of the applications of additive manufacturing technology in the automotive industry with a meta-synthesis review approach

Background and Objectives: Additive manufacturing, as one of the advanced production technologies, has gained a prominent place in the automotive industry in recent years. This method, by gradually adding materials and eliminating the need for traditional machining or molding processes, enables the production of parts with complex geometries, low weight, high strength, and customized designs. Reduced consumption of raw materials, minimized waste, improved technical performance, enhanced fuel efficiency, and achievement of environmental sustainability goals are among its most important advantages. The aim of the present study is to systematically identify and analyze the applications of additive manufacturing in the automotive industry and to present an integrated picture of the capacities, opportunities, and achievements of this technology.
Materials and Methods: This study was conducted with a qualitative approach using the meta‑synthesis method. Data were collected from the Web of Science database within the time span of 2015 to 2025, using the keywords “additive manufacturing,” “automotive industry,” and “applications of additive manufacturing.” After the initial search and screening, 214 articles were identified, which were reduced to 28 final articles based on inclusion and exclusion criteria, abstract reviews, and full‑text evaluation. Validation and quality control were performed using the Critical Appraisal Skills Programme (CASP) checklist, and only articles with a quality score of 7 out of 10 or higher were selected. Agreement between the two reviewers was confirmed with a Cohen’s kappa coefficient of 0.82, indicating a strong consensus in coding and data analysis.
Results: Based on the analysis of the selected articles, the most important applications of additive manufacturing in the automotive industry include: reducing vehicle weight to improve fuel efficiency, dynamic performance, and the range of electric vehicles; accelerating and reducing the cost of prototype production by up to 80% and eliminating the need for expensive molds; manufacturing complex and customized parts with advanced geometries; on‑site and on‑demand production of spare parts to reduce inventory costs and supply time; improving engine cooling and ventilation systems by creating complex channels and optimizing heat transfer; using composite materials and carbon fiber for lightweighting and enhancing aerodynamic stability; reducing waste and improving environmental indicators through the use of recycled materials; manufacturing parts and bodies in concept cars with high flexibility in design; and producing advanced molds to lower costs and shorten mass‑production timelines.
Conclusion: Additive manufacturing, with its ability to reduce material and energy consumption, increase production quality and speed, and realize innovative designs, has gained a strategic position within the automotive supply chain. This technology not only contributes to optimizing technical components and reducing environmental impacts but also facilitates the achievement of sustainable development goals. To fully exploit its potential, the adoption of practical approaches by automakers and policymakers is essential — including establishing sustainable collaborations between industry and academia, providing financial and legal support, developing innovation networks, and implementing technical standards and frameworks. Continuation of this trend could define a sustainable and competitive model for the global automotive industry.