The bio-compatible dental implant designed by using non-stochastic porosity produced by Electron Beam Melting® (EBM)

•An increase in the unit cell size resulted in a larger elastic deformation, while maximum tolerable biting force decreases.•An increase in the biting force angle is associated with increase in both deformation and maximum equivalent stress.•At biting force angles equal or above 30°, a considerable increase in the maximum equivalent stress is observed.•Octahedral lattice abutment with 2mm unit cell size was selected as the optimum design for dynamic loading investigation. The application of non-stochastic lattice structures for building a bio-compatible dental abutment is investigated. The bio-compatible dental implant should mimic the micro-motion of the natural tooth. Three different lattice structures including cross, honeycomb, and octahedral structures with different unit cell sizes were employed to produce lattice abutment made of Ti–6Al–4V by Electron Beam Melting® (EBM). According to the results, by increasing the unit cell size, abutments showed more deformation; however, the maximum tolerated normal force decreased. The octahedral lattice structure with 2mm unit cell size showed the best mechanical behavior under 400N normal biting force, and was selected to investigate the effect of biting force angle on the stress distribution developed in lattice abutment. Numerical analysis showed that α=30° is a critical biting force angle, for which the maximum equivalent stress increased noticeably.