Lavanya Rishi, Daljeet Singh, Vishal Srivastava, Vishal Gupta
Abstract This study provides a comprehensive review of the role of poly(lactic acid) (PLA) in fused deposition modeling (FDM) for biomedical additive manufacturing. PLA, a biodegradable and biocompatible polymer derived from renewable resources, has become a material of significant interest in healthcare. Its use spans orthopedic implants, including temporary plates, screws, pins and nails, which naturally degrade and eliminate the need for secondary surgeries required with nondegradable materials. In dentistry, FDM with PLA enables the fabrication of customized splints, temporary crowns, dentures and dental models, ensuring improved fit and patient comfort. PLA is also widely explored in tissue engineering scaffolds that promote bone and dental pulp regeneration. Despite these benefits, PLA has inherent limitations such as low mechanical strength and brittleness. FDM processing adds further challenges, including porous structures, weak interlayer bonding, limited resolution, warping and poor surface finish. Current research addresses these issues through fiber‐reinforced PLA composites with additives like hydroxyapatite, surface modification strategies and process optimization involving parameters such as layer height and raster angle. For clinical translation, rigorous mechanical testing (tensile, impact, torsion) and biological evaluations (cytocompatibility, in vivo degradation) remain essential. Overall, PLA demonstrates immense potential for personalized biomedical solutions, although advancements in materials and process refinement are crucial for overcoming existing challenges. © 2025 Society of Chemical Industry.