Additively manufactured heterogeneously porous metallic bone with biostructural functions and bone-like mechanical properties

Abstract A compatible artificial bone implant requires large pores for enhanced nutrients transports, small pores to allow cell seeding and bone-like mechanical properties to avoid stress shielding. Herein, we report novel improved gyroid lattices with millimetre-scaled gyroid wall spacings and micrometre-scaled additional pores on the walls. Designs are successfully fabricated by electron beam melting using Ti-6Al-4V to high part qualities while exhibiting bone-like mechanical properties with a range of Young’s modulus of 8-15 GPa and strength of 150-250 MPa. The improved design also eliminates brittle failure by allowing the structure to deform more stably.