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Indirect Fabrication of Lattice Metals with Thin Sections Using Centrifugal Casting
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Manufacturing-induced geometric deviations and corrosion-driven morphological evolution in magnesium lattice

Viviana M Posada-Perez1, Oscar Acevedo-Rueda2, Juan Ramírez2

  • 1Department of Electronics and Computer Science, Pontificia Universidad Javeriana, Cali, Colombia.

Journal of the Mechanical Behavior of Biomedical Materials
|April 17, 2026
PubMed
Summary

Manufacturing defects significantly alter lattice scaffold geometry, with corrosion further thinning struts but maintaining overall structure. Fabrication dictates initial shape and subsequent degradation patterns in metallic scaffolds.

Keywords:
Additive manufacturingCorrosionGeometric fidelityMagnesium scaffoldMicro-CTSalt templating

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Area of Science:

  • Materials Science
  • Biomaterials Engineering
  • Additive Manufacturing

Background:

  • Lattice scaffolds are crucial in biomedical applications, but their structural integrity is challenged by manufacturing variability and degradation.
  • Understanding geometric evolution during fabrication and corrosion is vital for predicting scaffold performance.

Purpose of the Study:

  • To quantify strut-level geometric changes in AZ31 alloy lattice scaffolds throughout manufacturing and corrosion.
  • To establish the relationship between fabrication-induced deviations and long-term morphological stability.

Main Methods:

  • Utilized Digital Light Processing (DLP) printing for resin templates and vacuum-assisted casting with NaCl molds for AZ31 alloy scaffolds.
  • Employed a micro-computed tomography (micro-CT) framework with voxel-wise thickness mapping and 3D deviation analysis.
  • Quantified geometric evolution during fabrication (resin to as-cast) and simulated physiological corrosion (DMEM).

Main Results:

  • Resin templates showed ~4% shrinkage; as-cast scaffolds exhibited an 8.8% size increase due to material redistribution, with deviations up to ±100 μm.
  • Fabrication introduced significant geometric deviations, particularly at nodes and unsupported strut segments.
  • Corrosion led to progressive strut thinning and Mg2+ release, but preserved the global lattice architecture.

Conclusions:

  • Manufacturing-induced geometric deviations are a primary determinant of lattice scaffold structural fidelity.
  • The developed micro-CT workflow effectively tracks structural evolution across fabrication and degradation.
  • Fabrication variability sets the stage for predictable, time-dependent morphological changes during scaffold use.