The transition toward Industry 5.0 has increased the need for intelligent, sustainable and human-centered manufacturing systems. In this context, additive manufacturing represents a key enabling technology for the development of personalized automotive components, due to its flexibility, digital workflow, material efficiency and capacity to support complex geometries and small-batch production.

This review analyzes the current research directions regarding the integration of additive manufacturing, artificial intelligence, human–machine collaboration and extended reality technologies within modern industrial systems. Particular attention is given to FFF processes, where the interaction between material properties, process parameters and equipment conditions strongly influences dimensional accuracy, inter-layer adhesion, porosity and mechanical performance. The paper also discusses the role of artificial intelligence in process monitoring, defect prediction, parameter optimization and decision support, highlighting its relevance for closed-loop and adaptive manufacturing systems.

From the perspective of Industry 5.0, the study emphasizes that the operator remains an essential element in the production system, especially in human-in-the-loop approaches. Technologies such as augmented reality, virtual reality, sensors and intelligent interfaces can support operator training, decision-making, ergonomic improvement and collaborative design. At the same time, the review identifies several research gaps, especially the limited integration of additive manufacturing, AI, human factors and AR/VR technologies into a unified framework for personalized automotive production.

The paper concludes that future intelligent additive manufacturing systems should combine process control, material knowledge, data-driven optimization and human-centered interaction in order to improve quality, flexibility, sustainability and resilience in automotive manufacturing.