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Structural influence on titanium ion dissolution in 3D-printed Ti6Al4V orthopedic implants
Eunhyeok Seo1, Yu Na Lee2, Woo Yeong Shin1
1Department of Mechanical Engineering, Ulsan National Institute of Science and Technology, UNIST-Gil 50, Ulsan, 44919, Republic of Korea.
Scientific Reports
|October 23, 2025
Summary
3D printed orthopedic implants can release harmful titanium ions due to mesh structures accelerating corrosion. This study highlights the need for careful design to ensure implant stability and patient safety.
Area of Science:
- Biomaterials Engineering
- Orthopedic Surgery
- Materials Science
Background:
- 3D printed orthopedic implants offer patient-specific solutions for bone tumors.
- Elevated titanium (Ti) ion levels are observed after surgery with 3D printed Ti6Al4V implants, risking toxicity and failure.
Purpose of the Study:
- To characterize titanium ion dissolution from 3D printed orthopedic implants.
- To investigate the impact of implant geometry and microstructure on Ti ion release.
Main Methods:
- Finite element analysis (FEA) of pelvic and tibial implants.
- Microstructural analysis of Ti6Al4V samples with varying geometries (solid, mesh, hybrid).
- Assessment of galvanic coupling between alpha (α) and beta (β) phases.
Main Results:
- Large mesh surface areas in implants accelerate corrosion.
- Galvanic coupling between α and β phases drives localized corrosion.
- Mesh structures exhibit higher β-phase content (145%-200%), promoting Ti ion release.
Conclusions:
- Mesh structures, while crucial for tissue integration, significantly increase Ti ion release.
- Ti ion release can compromise long-term mechanical integrity of 3D printed implants.
- Design and surface treatments are essential to balance osseointegration and material stability.
