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Owing to the possibility of direct processing of CAD models into three-dimensional objects, additive manufacturing (AM) is widely used in the production of individualized bone scaffolds that can lead to perfect restoration of anatomical structures of missing bone tissues. In this work, one of the AM technologies was applied, referred to as Electron Beam Melting (EBM), using Ti6Al4V ELI alloy to produce open-cell structures. Scaffold architecture influences its mechanical properties and is important from the point of view of biological considerations. To optimize mechanical properties, designed geometries were subjected to Finite Element Method analysis and experimental static compression tests. Also, geometric CT analysis of manufactured scaffolds was carried out (geometry deviations up to ± 300 µm). Obtained results have shown that AM can be used to produce Ti6Al4V ELI alloy scaffolds displaying mechanical parameters similar to those of bone tissue ( E  = 0.45–2.88 MPa). The EBM process affects the microstructure and macrostructural properties of manufactured parts, e.g., through internal porosities present in the material by to unmelted powder particles (internal porosity in range of 1.25–2.25%). To assess the quality and suitability of additively manufactured implants, a multidimensional verification of the impact of the manufacturing process on the properties of the final product was performed.

The effect of geometry on mechanical properties of Ti6Al4V ELI scaffolds manufactured using additive manufacturing technology