Nickel–titanium alloy porous scaffolds based on a dominant cellular structure manufactured by laser powder bed fusion have satisfactory osteogenic efficacy

Nickel–titanium (NiTi) alloy is a widely utilized medical shape memory alloy (SMA) known for its excellent shape memory effect and superelasticity. Here, laser powder bed fusion (LPBF) technology was employed to fabricate a porous NiTi alloy scaffold featuring a topologically optimized dominant cellular structure that demonstrates favorable physical and superior biological properties. Utilizing a porous structure topology optimization method informed by the stress state of human bones, two types of cellular structures—compression and torsion—were designed, and porous scaffolds were produced via LPBF. The physical properties of the porous NiTi alloy scaffolds were evaluated to confirm their biocompatibility, while their osteogenic efficacy was investigated through both in vivo and in vitro experiments, with comparisons made against a traditional octahedral unit cell structure. NiTi alloy porous scaffolds can be nearly net-shaped via LPBF and exhibit favorable physical properties, including a low elastic modulus, high hydrophilicity, a specific linear expansion rate, as well as superelastic and shape memory effects. These scaffolds demonstrate excellent biocompatibility, support in vitro osteogenesis, and possess significant in vivo bone ingrowth capabilities. When compared to titanium alloys, NiTi alloys show comparable osteogenic properties in vitro but superior bone ingrowth properties in vivo. Additionally, among octahedral-type, torsion-type, and topologically optimized compression-type porous scaffolds, the latter demonstrates enhanced bone ingrowth properties. LPBF technology is effective for manufacturing porous NiTi alloy scaffolds with fine pore structures and excellent mechanical properties. The scaffolds based on topologically optimized dominant cellular structures facilitate satisfactory and efficient bone formation.