Rationally designed functionally graded porous Ti6Al4V scaffolds with high strength and toughness built via selective laser melting for load-bearing orthopedic applications.

Functionally graded materials (FGMs) with porosity variation strategy mimicking natural bone are potential high-performance biomaterials for orthopedic implants. The architecture of FGM scaffold is critical to gain the favorable combination of mechanical and biological properties for osseointegration. In this study, four types of FGM scaffolds with different structures were prepared by selective laser melting (SLM) with Ti6Al4V as building material. All the scaffolds were hollow cylinders with different three-dimensional architectures and had gradient porosity resembling the graded-porous structure of human bone. Two unit cells (diamond and honeycomb-like unit cells) were used to construct the cellular structures. Solid support structures were embedded into the cellular structures to improve their mechanical performances. The physical characteristics, mechanical properties, and deformation behaviors of the scaffolds were compared systematically. All the as-built samples with porosities of ~52-67% exhibited a radial decreasing porosity from the inner layer to the outer layer, and their pore sizes ranged from ~420 to ~630 μm. The compression tests showed the Young's moduli of all the as-fabricated samples (~3.79-~10.99 GPa) were similar to that of cortical bone. The FGM structures built by honeycomb-like unit cells with supporting structure in outer layer exhibited highest yield strength, toughness and stable mechanical properties which is more appropriate to build orthopedic scaffolds for load-bearing application.