AUTHOR=Kök Hüray Ilayda , Andreeva Tonya , Stammkötter Sebastian , Reinholdt Cindy , Akbas Osman , Jahn Anne , Gamon Florian , Fuest Sandra , Teschke Mirko , Schäfer Miriam , Müller Michael , Koch Alexander , Jung Ole , Barbeck Mike , Greuling Andreas , Smeets Ralf , Hermsdorf Jörg , Krastev Rumen , Junker Philipp , Stiesch Meike , Walther Frank 

TITLE=Characterization and modeling of additively manufactured Ti-6Al-4V alloy with modified surfaces for medical applications

JOURNAL=Frontiers in Bioengineering and Biotechnology

VOLUME=Volume 13 - 2025

YEAR=2025

URL=https://www.frontiersin.org/journals/bioengineering-and-biotechnology/articles/10.3389/fbioe.2025.1526873

DOI=10.3389/fbioe.2025.1526873

ISSN=2296-4185

ABSTRACT=In the field of biomedical implants, additively manufactured titanium alloys, particularly Ti-6Al-4V, hold significant potential due to their biocompatibility and mechanical properties. This study focuses on the characterization and modeling of additively manufactured Ti-6Al-4V alloy for dental and maxillofacial implants, emphasizing fatigue behavior, surface modification, and their combined effects on cyto- and osseocompatibility. Experimental methods, including tensile, compression, and fatigue testing, were applied alongside in silico simulations to assess the long-term mechanical performance of the material. Surface properties were further modified through sandblasting and coating techniques to enhance cell adhesion and proliferation. By using in-vitro methods, the cytocompatibility of the coatings and materials was examined followed by in-vivo tests to determine osseocompatibility. Results demonstrated that appropriate surface roughness and modifications are essential in optimizing osseointegration, while the layer-by-layer additive manufacturing process influenced the fatigue life and stability. These findings contribute to the development of patient-specific implants, optimizing both mechanical integrity and biological integration for enhanced clinical outcomes. This work summarizes the investigations on additively manufactured Ti-6Al-4V alloy of the research unit 5250 “Mechanism-based characterization and modeling of permanent and bioresorbable implants with tailored functionality based on innovative in vivo, in vitro and in silico methods” funded by the Germany Research Foundation (DFG).