AUTHOR=Li Zhuangzhuang , Luo Yi , Liu Ruicheng , Zou Shanfang , Wang Yitian , Gong Taojun , He Xuanhong , Zhou Yong , Lu Minxun , Min Li , Tu Chongqi 

TITLE=Selective laser melting fabrication of functionally graded macro-porous Ti-6Al-4V scaffold for cavity bone defect reconstruction

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.2025.1550309

DOI=10.3389/fbioe.2025.1550309

ISSN=2296-4185

ABSTRACT=Reconstruction of cavitary bone defects poses significant challenges in orthopedic surgery due to the irregular shapes and compromised mechanical properties of surrounding bone. This study developed a functionally graded macro-porous scaffold (FGMPS) using selective laser melting (SLM) for cavitary bone defect reconstruction. The FGMPS featured a porosity gradient (74%–86%) and macropores ≥1,600 µm, mimicking the natural density gradient of cancellous bone. Micro-CT analysis confirmed high structural fidelity and interconnected porosity. Compression tests in two orientations revealed distinct stress-strain responses: vertically aligned gradients (FGMPS-V) exhibited sequential layer engagement, while horizontally aligned gradients (FGMPS-H) demonstrated higher stiffness and strength due to uniform load distribution. The elastic modulus ranged from 383 MPa (FGMPS-V) to 577 MPa (FGMPS-H), with yield strength of 22–40 MPa, aligning well with cancellous bone properties. These findings highlight the FGMPS’s potential to offer a promising solution for cavitary bone defect repair.