EBM-manufactured Ti6Al4V scaffolds for orthopaedic implants: mechanical, in-vitro biocompatibility and corrosion analysis in SBF

Abstract

Early loosening of the implant due to stress shielding is a critical issue for its functionality

however, modulating the Young's modulus can resolve this. This study investigates the mechanical, electrochemical, and biological performance of Ti6Al4V scaffolds fabricated using electron beam melting powder bed fusion process. The results have showed that the increasing porosity from 65% to 80% reduced the elastic modulus from 7.38 to 1.63 GPa, respectively, which can further reduce the risk of stress shielding. Electrochemical corrosion studies in simulated body fluid environment showed a decrease in corrosion resistance with increasing porosity due to increased surface area and electrolyte penetration. Cytotoxicity and cell culture results indicated that 70%–80% porous scaffolds showed 90% cell viability, indicating improved nutrient transport. This study concluded that scaffolds with 70% and 75% porosity showed an optimal balance of mechanical strength, corrosion resistance, and biocompatibility for load-bearing orthopaedic implants application. © 2026 Elsevier B.V.