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Related Experiment Video

Updated: May 12, 2025

Plasma Polishing as a New Polishing Option to Reduce the Surface Roughness of Porous Titanium Alloy for 3D Printing
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Preparation and Post-Processing of Three-Dimensional Printed Porous Titanium Alloys.

Tairong Li1, Mengyu Xu1, Jinzhi Yao2

  • 1College of Materials Science and Engineering, Fuzhou University, Fuzhou 350108, China.

Materials (Basel, Switzerland)
|May 7, 2025
PubMed
Summary

Selective laser melting optimized Ti6Al4V scaffolds for orthopedic implants. Chemical polishing effectively removed powder adhesion, enhancing biocompatibility and patient safety for porous titanium alloys.

Keywords:
3D printingchemical polishingmechanical propertiesporous titanium alloysselective laser melting (SLM)

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Area of Science:

  • Biomaterials Engineering
  • Orthopedic Implant Technology
  • Additive Manufacturing

Background:

  • Ti6Al4V is a preferred material for orthopedic implants due to its biocompatibility and mechanical strength.
  • Solid titanium implants' high elastic modulus causes stress shielding and loosening compared to bone.
  • Porous titanium alloys fabricated via additive manufacturing offer improved elasticity matching bone.

Purpose of the Study:

  • To optimize selective laser melting (SLM) parameters for Ti6Al4V fabrication.
  • To investigate the mechanical properties of SLM-produced porous Ti6Al4V scaffolds.
  • To develop an effective post-processing method for removing powder adhesion.

Main Methods:

  • Ti6Al4V samples were fabricated using SLM with varying scanning speeds (800-1400 mm/s) at a fixed laser power (200 W).
  • Cubic unit cell scaffolds with varied pore sizes (400-800 μm) and porosities (60%, 80%) were designed and tested.
  • Chemical polishing with a diluted HF-HNO3 solution was employed to remove adhered powder.

Main Results:

  • An optimal scanning speed of 1200 mm/s was identified for Ti6Al4V fabrication via SLM.
  • Scaffolds with 400 μm pore diameter and 60% porosity showed the highest compressive strength (794 MPa) and fracture strain (41.35%).
  • Optimal chemical polishing duration of 40 minutes effectively removed adhered powder without structural damage.

Conclusions:

  • Optimized SLM parameters and scaffold design can produce porous Ti6Al4V with desirable mechanical properties for orthopedic applications.
  • Chemical polishing is an effective method for addressing powder adhesion issues in SLM-produced porous titanium implants.
  • This research contributes to the development of safer and more effective porous titanium orthopedic implants.