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Updated: Jun 14, 2026
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Multi-Scale Modification of Metallic Implants With Pore Gradients, Polyelectrolytes and Their Indirect Monitoring In vivo
Published on: July 1, 2013
Next-generation biomedical implants using additive manufacturing of complex, cellular and functional mesh arrays.
L E Murr1, S M Gaytan, F Medina
1Department of Metallurgical and Materials Engineering, The University of Texas at El Paso, El Paso, TX 79968, USA. lemurr@utep.edu
Summary
This study explores additive manufacturing (AM) using electron beam melting (EBM) to create patient-specific bone implants. Optimized mesh designs in titanium alloys promote bone ingrowth for better cementless implant integration.
Area of Science:
- Biomedical Engineering
- Materials Science
- Additive Manufacturing
Background:
- Patient-specific implants are crucial for hard tissue replacement.
- Additive manufacturing (AM) offers novel fabrication methods for complex biomedical devices.
- Electron beam melting (EBM) is a promising AM technique for metallic implants.
Purpose of the Study:
- To investigate the potential of EBM for manufacturing patient-specific biomedical implants, focusing on bone replacements like knee/hip stems and femoral rods.
- To explore the fabrication of complex, functionally graded mesh arrays with varying densities for optimized bone ingrowth and cementless fixation.
- To analyze the relationship between mesh design, density, mechanical properties, and microstructure in Ti-6Al-4V implants.
Main Methods:
- Fabrication of Ti-6Al-4V prototypes using EBM with diverse mesh designs.
- Density and elastic (Young's) modulus determination via resonant frequency and damping analysis.
- Microstructural analysis (optical and electron metallography) and microindentation hardness testing.
- Utilizing CT scans of metal foam to create EBM models for Ti-6Al-4V foam fabrication.
Main Results:
- Successful fabrication of complex mesh arrays with varying densities using EBM of Ti-6Al-4V.
- Correlation established between mesh density, elastic modulus, and optimized bone ingrowth potential.
- Variations in mesh complexity and strut dimensions influenced cooling rates, leading to specific alpha-phase microstructures (alpha/alpha').
- Microindentation hardness measurements reflected the observed microstructures and their mixtures.
Conclusions:
- EBM is a viable method for producing patient-specific, functionally graded bone implants with tailored mechanical properties.
- Optimized mesh designs can enhance bone ingrowth, facilitating cementless implant fixation.
- Controlling microstructure through AM process parameters is key to achieving desired implant performance.
