Comparative In-Vivo and Ex-Vivo Performance of Bio-Inspired Materials Fabricated via PBF-LB for Biomedical Applications

Titanium-based lattice structures have gained significant attention in biomedical engineering due to their potential to mimic bone-like behavior and improve implant performance. This study evaluates the performance of bio-inspired Ti64 TPMS Gyroyd and Stochastic lattice structures fabricated via Powder Bed Fusion-Laser Beam (PBF-LB), focusing on their in-vivo and ex-vivo mechanical and biological responses for biomedical applications. Utilizing an SLM 280 HL printer, samples exhibited notable geometric accuracy essential for mechanical integrity. The study highlights significant mechanical properties and geometric precision improvements achieved through chemical etching. Mechanical characterization revealed that the as-built Gyroid lattice had the highest elastic modulus (3.64 GPa) and yield strength (200.65 MPa), which improved post-etching (3.62 GPa and 219.35 MPa, respectively). The Stochastic lattice demonstrated lower yield strength values post-etching (169.81 MPa). In-vivo analyses in horse models, both structures demonstrated excellent biocompatibility and osseointegration with no adverse inflammatory responses. Ex-vivo push-out tests showed that the chemically etched Gyroid structure achieved the highest resistance to push-out force (1645.407 N) and most significant displacement (2.754 mm), indicating superior energy absorption (4920.425 mJ). These findings underscore the critical influence of microstructural design and surface treatments on implant functionality, offering novel insights into improving biomedical implant performance through lattice architecture and post-processing.