3D-printed Ti6Al4V Research Articles

Applying 3D-Printed Porous Ti6Al4V Prostheses to Repair Osteomyelitis-Induced Partial Bone Defects of Lower Limbs: Finite Element Analysis and Clinical Outcomes.

The clinical management of partial bone defects in lower limbs, particularly those resulting from osteomyelitis, remains a significant challenge. This study aimed to systematically evaluate the effectiveness of 3D-printed porous Ti6Al4V prostheses in addressing osteomyelitis-induced partial bone defects. We established a comprehensive protocol for utilizing 3D-printed prostheses for bone defect repair, encompassing 3D simulation of prosthesis implantation and internal fixation, finite element analysis (FEA), and clinical implementation. Mimics software facilitated simulation of fixation patterns and screw lengths. FEA modeled bone defects in the distal metaphyseal femur and distal diaphyseal tibia to assess changes in stress conduction pre- and post-prosthesis implantation. The clinical study involved eight patients (average age: 56.3 years) with an average defect length of 14.9 cm. Postoperative outcomes were evaluated using X-rays and the Lower Extremity Functional Scale (LEFS). FEA demonstrated that the implanted prostheses effectively shared stress and reduced the load on residual bone in both models, thus lowering the risk of fractures under external forces. The average follow-up period was 24.5 months, with patients initiating weight-bearing activities on average 7.8 days post-surgery. Serial postoperative X-rays demonstrated long-term stability of the prostheses, with progressive bone regeneration around and integration with the prostheses. While two patients experienced infection recurrence requiring prosthesis removal and debridement, the remaining six showed significant improvement in LEFS scores, increasing from 31.5 preoperatively to 61.0 at the last follow-up. 3D-printed porous Ti6Al4V prostheses effectively restore anatomical integrity and optimize stress conduction in lower limbs, resulting in substantial functional recovery. This innovative approach shows promise for wider clinical adoption and warrants further investigation in medical practice.

Optimized Laser Surface Remelting of 3D-Printed Ti6Al4V Manufactured Through Electron Beam Melting

Optimized Laser Surface Remelting of 3D-Printed Ti6Al4V Manufactured Through Electron Beam Melting

Microstructure and strength of a 3D-printed Ti–6Al–4V alloy subjected to high-pressure torsion

Currently, one of the effective 3D printing methods is wire-feed electron-beam additive manufacturing (EBAM), which allows producing large-sized commercial billets from Ti–6Al–4V titanium alloy. However, Ti–6Al–4V alloy produced by this method demonstrates reduced strength properties. It is known that it is possible to increase the strength properties of metallic materials by refining their grain structure by high-pressure torsion (HPT). This work is aimed at studying the influence of high-pressure torsion on the microstructure, and mechanical strength of a structural Ti–6Al–4V titanium alloy produced by the wire-feed electron-beam additive manufacturing method. The microstructure of a 3D-printed Ti–6Al–4V alloy in the initial state, and after high-pressure torsion, was studied using optical, scanning and transmission electron microscopy. An EBSD analysis of the material in its original state was carried out. The microhardness of the material in the initial and deformed states was measured. Using the dependence of the yield strength on microhardness, the estimated mechanical strength of the material after processing by the high-pressure torsion method was determined. The microstructural features of the 3D-printed Ti–6Al–4V alloy after high-pressure torsion, which provide increased strength of this material, are discussed. The research results demonstrate that 3D printing, using the electron-beam additive manufacturing method, allows producing a Ti–6Al–4V titanium alloy with a microstructure unusual for this material, which consists of columnar primary β-grains with a transverse size of 1–2mm, inside of which martensitic α'-Ti needles are located. Thin β-Ti layers with a thickness of about 200nm are observed between the α'-Ti needles. Further deformation treatment of the alloy, using the high-pressure torsion method, allowed forming an ultrafine-grained structure in its volume, presumably consisting of α-grains with an average size of (25±10)nm. High-pressure torsion of the 3D-printed alloy allowed achieving rather high microhardness values of (448±5)НV0.1, which, according to the HV=2.8–3σy ratio, corresponds to the estimated yield strength of approximately 1460MPa.

Designs and mechanical responses of 3D-printed Ti6Al4V porous structures based on triply periodic minimal surfaces with different iso-values

With the increasing applications of additive manufacturing in orthopaedic implants and numerous designs of porous structures available, there is a strong need and opportunity to optimize the structure designs for improved bone integration. Here we created a unique group of sheet structures based on triply periodic minimal surface (TPMS) by varying the iso-value and systematically examined how iso-value influences the mechanical performance of sheet diamond TPMS structures compared to the Octet truss structure. Four iso-values (C) 0, 0.25, 0.5, and 0.75 were designed for sheet Diamond (OSD) TPMS with varying porosity, and Ti6Al4V powder bed fusion was used to produce the porous structures. Compressive tests revealed that iso-value C significantly affected mechanical performance, and interestingly, the impact was porosity-dependent. At high relative density (>0.25), OSD0 (C = 0) displayed the highest elastic modulus and yield strength, whereas at low relative density (<0.25), OSD0.5 showed the highest among all OSD structures. Regarding failure mechanisms, OSD0, OSD0.25, and OSD0.75 showed a mixed domination of stretching and bending, while OSD0.5 was predominantly stretching-dominated. Finite Element Analysis (FEA) found that local yielding initiated at cell nodes upon loading, followed by surface bending and the formation of single or multiple shear bands near the cell nodes. This work demonstrated the feasibility of improving the mechanical performance of porous TPMS structures by simple adjustments in their governing trigonometric functions, serving as a starting point to customize porous structures for specific applications.

Vancomycin-encapsulated hydrogel loaded microarc-oxidized 3D-printed porous Ti6Al4V implant for infected bone defects: Reconstruction, anti-infection, and osseointegration

Infected bone defect is a formidable clinical challenge. Conventional approaches to prevention and treatment for infected bone defects are unsatisfactory. The key elements of the treatment are bone defect reconstruction, anti-infection, and osteogenesis. Conventional treatment methods remain unsatisfactory owing to the absence of composite integrating materials with anti-infective, and osteogenic activities as well as proper mechanical strength at the same time. In this study, we fabricated a vancomycin-encapsulated hydrogel with bacteria-responsive release properties combined with a shaved porous (submicron-micron) three-dimensional-printed Ti6Al4V implant. The implant surface, modified with submicron-sized pores through microarc oxidation (MAO), showed enhanced osteogenic activity and integrated well with the hydrogel drug release system, enabling sustained vancomycin release. In vitro experiments underscored the commendable antibacterial ability, biosafety, and osteoinductive potential. Effective antibacterial and osteogenic abilities of the implant were further demonstrated in vivo in infected rabbit bone defects. These results showed that the vancomycin-encapsulated hydrogel-loaded microarc-oxidized 3D-printed porous Ti6Al4V can repair the infected bone defects with satisfactory anti-infection and osseointegration effects.

Biomimetic Porous Ti6Al4V Implants: A Novel Interbody Fusion Cage via Gel-Casting Technique to Promote Spine Fusion.

An interbody fusion cage (Cage) is crucial in spinal decompression and fusion procedures for restoring normal vertebral curvature and rebuilding spinal stability. Currently, these Cages suffer from issues related to mismatched elastic modulus and insufficient bone integration capability. Therefore, a gel-casting technique is utilized to fabricate a biomimetic porous titanium alloy material from Ti6Al4V powder. The biomimetic porous Ti6Al4V is compared with polyetheretherketone (PEEK) and 3D-printed Ti6Al4V materials and their respective Cages. Systematic validation is performed through mechanical testing, in vitro cell, in vivo rabbit bone defect implantation, and ovine anterior cervical discectomy and fusion experiments to evaluate the mechanical and biological performance of the materials. Although all three materials demonstrate good biocompatibility and osseointegration properties, the biomimetic porous Ti6Al4V, with its excellent mechanical properties and a structure closely resembling bone trabecular tissue, exhibited superior bone ingrowth and osseointegration performance. Compared to the PEEK and 3D-printed Ti6Al4V Cages, the biomimetic porous Ti6Al4V Cage outperforms in terms of intervertebral fusion performance, achieving excellent intervertebral fusion without the need for bone grafting, thereby enhancing cervical vertebra stability. This biomimetic porous Ti6Al4V Cage offers cost-effectiveness, presenting significant potential for clinical applications in spinal surgery.

3D-printed Ti6Al4V thoracic fusion cage: Biomechanical behavior and strengthening mechanism

To effectively replace diseased and damaged thoracic vertebrae, a series of three-dimensional (3D) printed titanium (Ti) alloy (Ti6Al4V) thoracic fusion cages with varying volume ratio of reinforced scaffolds are designed, and their structure-function relationships are investigated systematically. It is demonstrated that the mechanical strength of fusion cage is gradually enhanced as the scaffold volume increases, which may be attributed to its textural transformation from α phase to β phase. The compressive, shear, and fatigue of fusion cages successfully attain the International Organization for Standardization (ISO 23089), when the scaffold volume ratio exceeds 15%. Furthermore, the biomechanical analyses, including stress distributions and subsidence in flexion, extension, axial rotation, and lateral bending sections of fusion cages, further shed light on their potential clinical applications. This work deeply deciphers the intrinsic connection between biomechanical property and material texture of the thoracic fusion cages, offering valuable insights into their strengthening mechanism, which providing a guidance for the precise design and quick synthesis of other 3D-printed Ti6Al4V implants.

Wear resistance and antibacterial properties of 3D-printed Ti6Al4V alloy after gas nitriding

This research focused on tribological and antibacterial studies of 3D-printed Ti6Al4V alloys based on the selective laser melting method vs conventional technology after gas nitriding for biomedical applications. Gas nitriding reduced friction and wear in the following order: 3D-printed AM Ti6Al4V > wrought CM Ti6Al4V > CP-Ti. The best tribological performance was demonstrated on nitrided Ti6Al4V alloy using 3D printing. The antibacterial activity of the samples was estimated for the Gram-positive Staphylococcus aureus and the Gram-negative bacteria Escherichia coli. AM Ti6Al4V showed a positive antibacterial effect of nitriding against S. aureus bacteria by up to 30 %. Gas nitriding of 3D-printed Ti6Al4V alloys suggests an effective strategy to improve the antibacterial activity and mechanical resistance of biomedical implants.

Calcium Phosphate Coatings Deposited on 3D-Printed Ti–6Al–4V Alloy by Plasma Electrolytic Oxidation

In this article, the process of creating calcium phosphate coatings through plasma electrolytic oxidation was investigated. Calcium phosphate coatings were deposited onto titanium substrates fabricated via the selective laser melting (SLM) method. The correlation between the characteristics of the coating and the applied voltage (200, 250, and 300 V) of PEO was studied. The surface morphology analysis indicates that an increase in applied voltage results in a larger pore size. It was discovered that, when a voltage of 300 V was applied, a layer of hydroxyapatite formed. However, at 300 V, the coating cracked, producing a significantly rough surface. Our analysis of the elemental composition of sample cross sections indicates the presence of TiO2 layers that are enriched with calcium (Ca) and phosphorus (P). The coefficient of friction and wear rate are primarily influenced by the morphology, pore size, and density of the titanium dioxide layer. Furthermore, a rise in the quantity of the beta phase of the titanium on the surface can be noticed as the applied voltage increases. As a result, it also affects the mechanical and tribological characteristics of the coating. The sample treated to a voltage of 250 V demonstrates a higher resistance to wear and a lower elastic modulus in comparison to the other two coatings.

Comparison of the biomechanical behavior between commercial and 3D-printed patient-specific Ti6Al4V L-Shaped titanium plates following le fort i osteotomy using finite element analysis: A technical Note

ObjectiveTo evaluate and compare the biomechanical behavior of three-dimensionally (3D) printed patient-specific Ti6Al4V with commercially made titanium mini plates following Lefort-I osteotomy using finite element analysis. MethodsLe Fort I osteotomy was virtually simulated with a 5 mm maxillary advancement and mediolateral rotation in the coronal plane, resulting in a 3 mm gap on the left side's posterior. Two fixation methods were modeled using software to compare 3D-printed Ti6Al4V and commercial titanium mini plates, both featuring a 4-hole l-shape with thicknesses of 0.5 mm and 0.7 mm at the strategic piriform rim and zygomaticomaxillary buttress locations. Using ANSYS R19.2, finite element models were developed to assess the fixation plates and maxilla's stress, strain, and displacement responses under occlusal forces of 125, 250, and 500 N/mm². ResultsThis comparative analysis revealed slight variation in stress, strain, and displacement between the two models under varying loading conditions. Stress analysis indicated maximum stress concentrations at the vertical change in the left posterior area between maxillary segments, with the Ti6Al4V model exhibiting slightly higher stress values (187 MPa, 375 MPa, and 750 MPa) compared to the commercial titanium model (175 MPa, 351 MPa, and 702 MPa). Strain analysis showed that the commercial titanium model recorded higher strain values at the bending area of the l-shaped miniplate. Moreover, displacement analysis revealed a maximum of 3 mm in the left posterior maxilla, with the Ti6Al4V model demonstrating slightly lower displacement values under equivalent forces. ConclusionThe maximum stress, strain, and segment displacement of both fixation models were predominantly concentrated in the area of the gap between the maxillary segments. Notably, both fixation models exhibited remarkably close values, which can be attributed to the similar design of the fixation plates.

Coatless modification of 3D-printed Ti6Al4V implants through tailored Cu ion implantation combined with UV photofunctionalization to enhance cell attachment, osteogenesis and angiogenesis

The three-dimensional-printed Ti6Al4V implant (3DTi) has been widely accepted for the reconstruction of massive bone defects in orthopedics owing to several advantages, such as its tailored shape design, avoiding bone graft and superior bone-implant interlock. However, the osteoinduction activity of 3DTi is inadequate when applied clinically even though it exhibits osteoconduction. This study developes a comprehensive coatless strategy for the surface improvement of 3DTi through copper (Cu) ion implantation and ultraviolet (UV) photofunctionalization to enhance osteoinductivity. The newly constructed functional 3DTi (UV/Ti-Cu) achieved stable and controllable Cu doping, sustained Cu2+ releasing, and increased surface hydrophilicity. By performing cellular experiments, we determined that the safe dose range of Cu ion implantation was less than 5×1016 ions/cm2. The implanted Cu2+ enhanced the ALP activity and the apatite formation ability of bone marrow stromal cells (BMSCs) while slightly decreasing proliferation ability. When combined with UV photofunctionalization, cell adhesion and proliferation were significantly promoted and bone mineralization was further increased. Meanwhile, UV/Ti-Cu was conducive to the migration and angiogenesis of human umbilical vein endothelial cells (HUVECs) in vitro, theoretically facilitating vascular coupling osteogenesis. In conclusion, UV/Ti-Cu is a novel attempt to apply two coatless techniques for the surface modification of 3DTi. In addition, it is considered a potential bone substrate for repairing bone defects.

Yield strength evaluation of 3D-printed Ti–6Al–4V components based on non-contact eddy-current measurement

The demand for metal additive manufacturing (AM), also known as three-dimensional (3D) printing, is increasing owing to its ability to produce components with complex shapes, heterogeneous material properties, low material waste, etc. However, for broader acceptance of metal AM, quality assurance of mechanical properties, such as elastic (Young's) modulus, Poisson's ratio, and ductility, is becoming critical in additively manufactured components. This study proposes a non-contact, non-destructive and automated eddy-current technique for yield strength estimation of additively manufactured Ti–6Al–4V components with the potential for online operation during metal AM. After conducting the eddy-current measurement at a specific inspection point within the Ti–6Al–4V component, the relationship between the eddy-current phase value and electrical conductivity is established. Subsequently, the yield strength of the Ti–6Al–4V component is estimated by utilizing the analytical relationship between yield strength and electrical conductivity, which is based on Andrew's research and the Hall–Petch relationship. For experimental validation, Ti–6Al–4V test specimens with different electrical conductivities (yield strengths) were fabricated by adjusting the cooling rate during metal direct energy deposition AM. Then, the yield strengths estimated using the proposed technique were compared with those obtained using conventional destructive tensile tests. The results show that the proposed technique can estimate the yield strength with an error rate of less than 8%. The uniqueness of this study lies in (1) the theoretical derivation of the relationship between the eddy-current phase value and yield strength, (2) non-destructive, non-contact, and automated estimation of the yield strength using eddy-current measurements, and (3) performance evaluation using additively manufactured Ti–6Al–4V specimens with different yield strengths.

Effect of lattice type on biomechanical and osseointegration properties of 3D-printed porous Ti6Al4V scaffolds

Porous structure is an efficient tool for optimizing the elastic modulus and osseointegration properties of titanium alloy materials. However, the investigations on pore shape remain scarce. In this study, we created porous Ti6Al4V scaffolds with a pore size of 600 &amp;mu;m but different lattices (cubic pentagon, diamond, cuboctahedron). The mechanical and biological properties of the scaffolds were investigated in static simulation analysis, in vitro mechanical compression test, computational fluid dynamics, as well as cell and animal experiments. The results demonstrated that the calculated yield strength difference between the three Ti6Al4V porous scaffolds was negligible, at approximately 140 MPa, allowing them to match the strength requirements of human bones. The diamond scaffold has the lowest calculated elastic modulus (11.6 GPa), which is conducive for preventing stress shielding. The shear stress was largely concentrated in the diamond scaffold, and the stress range of 120&amp;ndash;140 MPa accounted for the greatest share. The mouse MC3T3-E1 cells were found to attach to all three scaffolds, with the diamond scaffold displaying a higher degree of cell adherence. There was more proliferating cells on the diamond and cubic pentagon scaffolds than on the cuboctahedron scaffolds (P &lt; 0.05). The diamond scaffold exhibited the highest alkaline phosphatase activity and calcium salt accumulation in cell differentiation tests. Besides, the expression of osteogenic genes on the diamond scaffold was higher than that on the cuboctahedron scaffold, the cubic pentagon scaffold displaying the lowest expression. The in vivo studies revealed that all three scaffolds fused well with the surrounding bone and that there was no loosening or movement of the prosthesis. Micro-computed tomography, corroborated by the staining results of hard tissues, revealed that the level of new bone formation was the highest in the diamond scaffold, followed by the cuboctahedron scaffold (P &lt; 0.05). Taken together, the diamond scaffold is comparatively better at optimizing the elastic modulus and osseointegration properties of titanium alloy materials, and thus is a preferred choice for porous design.

Synthesis of TiO2 Nanotube Arrays on 3D-Printed Structures for Application as Fischer-Tropsch Synthesis Catalysts

In this work, 3D-printed Ti6Al4V structures are used as substrates to synthesize TiO2 nanotube arrays by electrochemical anodization. These nanostructured materials are used as supports for bimetallic FeCo catalysts in...

Advancing biomedical substrate engineering: An eco-friendly route for synthesizing micro- and nanotextures on 3D printed Ti–6Al–4V

This study investigates the impact of a combined approach involving sandblasting and electrochemical surface treatment using a deep eutectic solvent Ethaline, a eutectic mixture of choline chloride and ethylene glycol, on the surface characteristics of Ti–6Al–4V biomedical substrates fabricated through direct selective laser melting (DSLM). Research has focused on surface morphology, topography, chemical composition, and cell adhesion. The novel approach demonstrated the ability to create a hierarchical surface structure with both micro and nanopatterns. The rough edges resulting from the sandblasting process were effectively smoothed through subsequent electrochemical processing. Additionally, the issue of residual sand particles, which commonly arise in sandblasting procedures, was successfully addressed with the new method. The results indicated that Ti alloy samples subjected to sandblasting and electrochemical treatment in Ethaline exhibited improved surface hydrophilicity. In-vitro cell adhesion tests confirmed the potential for bio-inspired properties of DSLM-printed Ti–6Al–4V biomedical substrates achieved through the combination of sandblasting and electrochemical processing in Ethaline.

Performance of additively manufactured Ti6Al4V ELI finger joints: biomechanical testing and evaluation for arthritis management

Abstract Approximately 24 out of every 100 adults in the United States, or 58.5 million people, have arthritis, which refers to a condition that causes pain and inflammation in a joint according to US National Center for Chronic Disease Prevention and Health Promotion. Osteoarthritis is the most common type of arthritis, and it may damage almost any joint but mainly occur in hands, hips and knees. While there are several joint replacement options for hips and knees, there are only limited options for finger joints. In this paper, we report on several aspects of testing of novel finger joints: testing apparatus design, cadaveric performance test and material testing results of titanium joints using 3D-printed Ti6Al4V extra low interstitial (ELI). Soft cadaveric hands with finger joints were surgically replaced by additively manufactured titanium joints following the exact same anatomy of the cadavers. These small joints were engineered to mimic the biological and natural movements of fingers. The apparatus, methodology and results of biomechanical tests were deployed to evaluate and validate the joints particularly those of titanium joints manufactured via laser powder bed fusion methods (PBF-L/M).

Relative assessment of the microstructure, properties and bioactivity of 3D-printed and rolled Ti6Al4V with micro-arc oxidation (MAO) and hydrothermal (HT) treatment

The surface modification of 3D printed Ti6Al4V (3D-Ti64) and rolled Ti6Al4V (RO-Ti64) was carried out using optimized micro-arc oxidation (MAO) and hydrothermal (HT) treatment processes. The results showed that the 3D-Ti64 coating had a typical porous structure that was identical to the phase composition of the RO-Ti64 coating, and both exhibited super hydrophilic properties (contact angle of 0°). It was found that the 3D-Ti64 coating (1.40 × 10−7A/cm2, 39.38 MPa) had greater corrosion current density and adhesion strength compared to the RO-Ti64 coating (0.76 × 10−7A/cm2, 33.69 MPa). In addition, the HAP crystals formed by 3D-Ti64 and RO-Ti64 coatings after being cultured in SBF were not significantly different, indicating that both coatings had comparable in vitro bioactivity. However, the 3D-printed porous Ti64 coating formed a porous structure only around the edges, while the central region had a flocculent structure with unfinished electrolytic oxidation. Moreover, it was found that more HAP crystals were formed in the edge region after HT treatment. In short, the MAO and HT treatment parameters optimized on rolled Ti alloys can be inherited for continued use on 3D-printed Ti alloy solids. However, more considerations may need to be made for the 3D printing of porous Ti alloys.

Icariin-loaded 3D-printed porous Ti6Al4V reconstruction rods for the treatment of necrotic femoral heads.

Avascular necrosis of the femoral head is a prevalent hip joint disease. Due to the damage and destruction of the blood supply of the femoral head, the ischemic necrosis of bone cells and bone marrow leads to the structural changes and the collapse of the femoral head. In this study, an icariin-loaded 3D-printed porous Ti6Al4V reconstruction rod (referred to as reconstruction rod) was prepared by 3D printing technology. The mechanical validity of the reconstruction rod was verified by finite element analysis. Through infilling of mercapto hyaluronic acid hydrogel containing icariin into the porous structure, the loading of icariin was achieved. The biological efficacy of the reconstruction rod was confirmed through in vitro cell experiments, which demonstrated its ability to enhance MC3T3-E1 cell proliferation and facilitate cellular adhesion and spreading. The therapeutic efficacy of the reconstruction rod was validated in vivo through a femoral head necrosis model using animal experiments. The results demonstrated that the reconstruction rod facilitated osteogenesis and neovascularization, leading to effective osseointegration between bone and implant. This study provides innovative strategy for the treatment of early avascular necrosis of the femoral head. STATEMENT OF SIGNIFICANCE: The bioactivity of medical titanium alloy implants plays an important role in bone tissue engineering. This study proposed a medicine and device integrated designed porous Ti6Al4V reconstruction rod for avascular necrosis of the femoral head, whose macroscopic structure was customized by selective laser melting. The bionic porous structure of the reconstruction rod promoted the growth of bone tissue and formed an effective interface integration. Meanwhile, the loaded icariin promoted new bone and vascular regeneration, and increased the bone mass and bone density. Therefore, the implantation of reconstruction rod interfered with the further development of necrosis and provided a positive therapeutic effect. This study provides innovative strategies for the treatment of early avascular necrosis of femoral head.

Effect of Ultrasonic Impact Treatment on Microstructure and Fatigue Life of 3D Printed Ti–6Al–4V Titanium Alloy

Effect of Ultrasonic Impact Treatment on Microstructure and Fatigue Life of 3D Printed Ti–6Al–4V Titanium Alloy

Atomic Layer Deposition of Tantalum Oxide Films on 3D-Printed Ti6Al4V Scaffolds with Enhanced Osteogenic Property for Orthopedic Implants.

There is an evident advantage in personalized customization of orthopedic implants by 3D-printed titanium (Ti) and its alloys. However, 3D-printed Ti alloys have a rough surface structure caused by adhesion powders and a relatively bioinert surface. Therefore, surface modification techniques are needed to improve the biocompatibility of 3D-printed Ti alloy implants. In the present study, porous Ti6Al4V scaffolds were manufactured by a selective laser melting 3D printer, followed by sandblasting and acid-etching treatment and atomic layer deposition (ALD) of tantalum oxide films. SEM morphology and surface roughness tests confirmed that the unmelted powders adhered on the scaffolds were removed by sandblasting and acid-etching. Accordingly, the porosity of the scaffold increased by about 7%. Benefiting from the self-limitation and three-dimensional conformance of ALD, uniform tantalum oxide films were formed on the inner and outer surfaces of the scaffolds. Zeta potential decreased by 19.5 mV after depositing tantalum oxide films. The in vitro results showed that the adhesion, proliferation, and osteogenic differentiation of rat bone marrow mesenchymal stem cells on modified Ti6Al4V scaffolds were significantly enhanced, which may be ascribed to surface structure optimization and the compatibility of tantalum oxide. This study provides a strategy to improve the cytocompatibility and osteogenic differentiation of porous Ti6Al4V scaffolds for orthopedic implants.