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This review aims to assess the current modelling and experimental achievements in the design for additive manufacturing of bonded joints, providing a summary of the current state of the art. To limit its scope, the document is focused only on polymeric additive manufacturing processes. As a result, this review paper contains a structured collection of the tailoring methods adopted for additively manufactured adherends and adhesives with the aim of maximizing bonded joint performance. The intent is, setting the state of the art, to produce an overview useful to identify the new opportunities provided by recent progresses in the design for additive manufacturing, additive manufacturing processes and materials’ developments.

The work illustrates how building parameters of the Additive Manufacturing process Fused Filament Fabrication can affect not only the mechanical properties but also the surface wettability and morphology. Wettability and morphology are relevant factors in bonded joints performance. Advantages of polymeric additive manufacturing are to allow a re-design of components with locally controlled properties and integrated functions. Major limitations are related to the lack of material testing standardization and constraints due to the build volume and to the object orientation for printability: the latter problem scan be addressed with the use of bonded joints that allow to create bigger assemblies from smaller parts optimally designed to take advantage of material orthotropy and without the structural drawbacks. In this study, two materials are considered, acrylonitrile butadiene styrene and polylactideacid. Wettability, surface morphology and mechanical strength have been determined at different combinations of nozzle temperature, print speed and layer thickness.

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