Selective laser melting processed Ti6Al4V lattices with graded porosities for dental applications.

Dental implants need to support good osseointegration into the surrounding bone for full functionality. Interconnected porous structures have a lower stiffness and larger surface area compared with bulk structures, and therefore are likely to enable better bone-implant fixation. In addition, grading of the porosity may enable large pores for ingrowth on the periphery of an implant and a denser core to maintain mechanical properties. However, given the small diameter of dental implants it is very challenging to achieve gradations in porosity. This paper investigates the use of Selective Laser Melting (SLM) to produce a range of titanium structures with regular and graded porosity using various CAD models. This includes a novel 'Spider Web' design and lattices built on a diamond unit cell. Well-formed interconnecting porous structures were successfully developed in a one-step process. Mechanical testing indicated that the compression stiffness of the samples was within the range for cancellous bone tissue. Characterization by scanning electron microscopy (SEM) and X-ray micro-computed tomography (μCT) indicated the designed porosities were well-replicated. The structures supported bone cell growth and deposition of bone extracellular matrix.