Influence of Processing Parameters on Additively Manufactured Architected Cellular Metals: Emphasis on Biomedical Applications.

Abstract

Laser powder bed fusion (LPBF) has emerged as a transformative additive manufacturing technique for fabricating architected cellular metallic structures, offering tailored properties for diverse biomedical applications. These structures are particularly well-suited for bone implants, scaffolds, and other load-bearing medical devices due to their ability to achieve lightweight designs, enhanced mechanical properties, and customized geometries. However, the complex interactions between LPBF process parameters and the resulting structural and mechanical properties pose significant challenges in achieving the precision and reliability required for clinical applications. This review provides a comprehensive analysis of the effects of LPBF process parameters, including laser power, scanning speed, and layer thickness, on key attributes such as dimensional accuracy, density, surface roughness, and microstructure. Their influence on the mechanical performance, including strength, fatigue resistance, and functional properties, is critically examined, with specific attention to biomedical relevance. The impact of lattice design factors, such as topology, unit cell size, and orientation, is also discussed, underscoring their role in optimizing biocompatibility and structural integrity for medical applications. Challenges such as surface defects, geometric inaccuracies, and microstructural inconsistencies are highlighted as key barriers to the broader adoption of LPBF in biomedical fields. Future perspectives focus on advancing LPBF technologies through process optimization and integration with advanced computational tools, such as machine learning, to enable efficient manufacturing of complex, patient-specific architectures. By addressing these challenges, LPBF has the potential to revolutionize the development of next-generation biomaterials, tailored to meet evolving clinical needs and improve patient outcomes.