Design and Mechanical Evaluation of Ti-6Al-4V Reticular Structures for Biomedical Implants

This study explores the additive manufacturing of porous Ti-6Al-4V reticular structures using Powder Bed Fusion Laser Beam, with a focus on their morphological and mechanical properties for biomedical implant applications. Three triply periodic minimal surface (TPMS) designs— diamond, primitive, and split-P—were fabricated with both constant and radial density gradients, and subjected to electropolishing and chemical etching to enhance surface quality. The results showed that split-P structures exhibited the highest yield strength (274.93–288.95 MPa) and a moderate Young’s modulus (7.16–7.76 GPa), making them strong candidates for load-bearing implants due to their mechanical behavior closely resembling that of trabecular bone. Diamond structures had the highest stiffness (6.95–8.65 GPa) but showed brittle behavior, while primitive structures presented the lowest modulus and strength, offering ductility suitable for flexible applications. The findings underscore the potential of optimized TPMS lattices to improve mechanical compatibility and reduce stress shielding in next-generation orthopedic implants.