Fabrication of multiple-layered gradient cellular metal scaffold via electron beam melting for segmental bone reconstruction

Abstract

The triple- and double-layered mesh Ti-based alloy scaffolds were successfully fabricated using electron beam melting (EBM). In this study Ti-based alloy cylindrical scaffolds with different 3D architectures intended for the segmental bone defect treatment were systematically compared. All lattice-like scaffolds were additively manufactured using EBM technology from Ti6Al4V to mimic the structures of human trabecular bone. Cylindrically-shaped lattice scaffolds (outer diameter of 15mm and length of 35mm) of five different types were designed and manufactured. Four types were tubular with inner hole diameter of 5mm and two lattice layers of different density. Fifth type was cylindrical with three lattice layers of different density. In all samples outer lattice layer was most dense, and inner layers- least dense. Mechanical properties of scaffolds were determined by conducting uniaxial compression testing. The strain-stress curves for all samples with gradient porosities showed considerable ductility.