Improved quality and functional properties of Ti-6Al-4V ELI alloy for personalized orthopedic implants fabrication with EBM process

Understanding the manufacturing process parameters and their correlation with final product functional properties is needed to ensure performance in critical applications in the medical industry. This article presents the holistic procedure for verifying the quality of manufactured products, including the determination of basic material characteristics and strength parameters based on EBM (Electron Beam Melting) technology for the titanium alloy Ti-6Al-4V ELI. The aim of this study was to investigate the effects of the manufacturing and post-processing methods used, on the geometric accuracy, microstructure, mechanical and cytotoxic properties of additively manufactured parts, especially in the form of personalized jaw implants. The effect of Hot Isostatic Pressing (HIP) treatment on microstructure and properties is also taken into account. The EBM manufacturing process was developed and samples were built using three different orientations: 0° (horizontally), 45° (diagonally), and 90° (vertically). The novel results are systematically presented and discussed beginning from the selection of process parameters, sample manufacturing, wide microstructural characterization, determination of static mechanical properties as well as geometric accuracy, and quality control verification depending on the manufacturing process and the post-processing methods used. The conducted research allowed for the presentation of the entire process chain of the EBM manufactured medical implant made of high-purity titanium alloy (Ti-6Al-4V ELI), thus filling the scientific gaps related to the selective presentation and discussion of research results published in the literature on the subject.