Fabrication of multiple-layered gradient cellular metal scaffold via electron beam melting for segmental bone reconstruction

The triple- and double-layered mesh Ti-based alloy scaffolds were successfully fabricated using electron beam melting (EBM). In this study Ti-based alloy cylindrical scaffolds with different 3D architectures intended for the segmental bone defect treatment were systematically compared. All lattice-like scaffolds were additively manufactured using EBM technology from Ti6Al4V to mimic the structures of human trabecular bone. Cylindrically-shaped lattice scaffolds (outer diameter of 15 mm and length of 35 mm) of five different types were designed and manufactured. Four types were tubular with inner hole diameter of 5 mm and two lattice layers of different density. Fifth type was cylindrical with three lattice layers of different density. In all samples outer lattice layer was most dense, and inner layers- least dense. Mechanical properties of scaffolds were determined by conducting uniaxial compression testing. The strain-stress curves for all samples with gradient porosities showed considerable ductility.