Microstructure and mechanical characterization of direct metal laser sintered Ti-6Al-4V alloy for orthopedic implant applications

Additive manufacturing (AM) technologies like direct metal Laser sintering (DMLS) or powder bed fusion technologies enable the fabrication of complex-shaped biomedical implants. Since process parameters influence the microstructure and thus, mechanical properties of a built structure, optimizing the parameters to produce implants that can withstand the imposed biomechanical forces is necessary. In this study, biocompatible Ti-6Al-4 V samples were fabricated using nine different combinations of process parameters for DMLS technology. The optimal printing parameters were determined using mechanical and microstructural analysis of printed samples. The mechanical and microstructure analysis revealed that parts built with volumetric energy density input of 37–93 J/mm3 are nearly defect-free and suitable for biomedical implant applications. [Display omitted]