Qualification of an Additive-Subtractive Process for Medical Implants Via Powder Bed Fusion of Commercially Pure Titanium Using a Laser Beam

Additive manufacturing with powder bed fusion of metals using a laser beam (PBF-LB/M) enables the manufacturing of complex medical implant geometries, such as patient-specific dental implants that replicate the shape of natural tooth roots. Such geometries may support improved osseointegration in the jawbone. This study investigates commercially pure titanium grade 2 (TiGd2) produced by PBF-LB/M as the basis of an additive-subtractive process for medical implants. Specimens were manufactured in different build orientations (BO) to assess material and surface properties. Micro computed tomography indicated a low internal defect density. Tensile testing showed BO dependent anisotropy, whereas compression testing showed no pronounced anisotropy. Across all BO, mean values were ultimate tensile strength RM = 772 MPa, elongation at break A = 24.4 %, and compressive yield strength R_dp = 746 MPa. Surface post processing enabled adjustment of roughness, with Ra decreasing from Ra_as = 6.3 µm in the as built state to Ra_pb = 5.1 µm after particle blasting, Ra_et = 3.6 µm after acid etching, and Ra_df = 0.36 µm after disc finishing. Overall, the results confirm the potential of PBF-LB/M processed TiGd2 for additive subtractive manufacturing of medical implants.