Strategic Control of Porosity and Post‐Processing in Additive Manufacturing of Metallic Bone Scaffolds

Healthy bones are strong and can endure considerable force, yet they may fracture under extreme pressure. Common causes of bone fractures include physical trauma, accidents, and conditions like osteoporosis that weaken bone integrity. Recent advancements in medical technology have enabled the use of metallic scaffolds to treat bone fractures. Metal additive manufacturing (also known as 3D printing) allows for the production of highly customized scaffolds. However, the mechanical and surface properties of 3D‐printed scaffolds are often inadequate for direct implantation into the human body. Various factors, including composition, hydrophilicity, surface roughness, porosity, Young's modulus, and mechanical stiffness, influence scaffold efficacy. Achieving the necessary properties of metallic scaffolds involves regulating porosity and employing suitable post‐processing procedures. The present review aims to evaluate methods for controlling porosity and post‐processing techniques, such as coating, chemical etching, laser polishing, mechanical finishing, and heat treatment for metallic scaffolds. These post‐processing methods play a significant role in producing effective metallic scaffolds by improving their mechanical and surface properties, as well as enhancing their biocompatibility. The review also highlights optimal porosity control and post‐processing techniques in metallic scaffolds to enhance their properties for bone fracture treatment.