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<p>Powder bed fusion-laser beam (PBF-LB) has emerged as a promising route for fabricating complex, patient-specific metallic implants with controlled architectures and tailored mechanical properties. In recent years, significant studies have been reported on the effects of infill patterns (IPs), scan strategies (SSTs), powder recyclability, and process parameters (such as laser power, scanning speed, and energy density) on the microstructure and mechanical performance of PBF-LB-fabricated biocompatible alloys. However, the collective impact of SSTs, IPs, and powder recyclability (which better reflects realistic processing conditions) remains largely unexplored, particularly for biomedical implant applications. In the present work, a Taguchi-based design of experiments (DOE) was employed to systematically investigate the effects of SSTs, IPs, and powder condition (virgin, primary, secondary recycled) on the process stability, microstructural evolution, and mechanical behavior of PBF-LB-fabricated 17-4 precipitate hardened (PH) stainless steel (SS) functional prototypes. Results reveal that among the selected input parameters for PBF-LB, the sample fabricated with virgin (V) powder, rectangular alternate (RA) as SST, and solid (SD) as IP exhibited the highest peak load of 16.04 kN. In comparison, the primary recycled (PR) powder sample, with stripe alternate (SA) as SST and Weaire-Phelan (WP) as IP, exhibited the lowest peak load of 10.04 kN. Overall, the study demonstrates the collective impact of SSTs, IPs, and powder recyclability in tailoring PBF-LB-fabricated 17-4 PH SS functional prototypes for cranio-maxillofacial implant applications.</p>

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On Powder Bed Fusion-Laser Beam-Based Functional Prototypes: Effect of Metastructure, Powder Recycling, and Scanning Strategy

  • 期刊论文

  • 发表日期：

    2026年4月24日

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  • Ravinder Singh,
  • Rupinder Singh,
  • I. P. S. Ahuja

摘要

Powder bed fusion-laser beam (PBF-LB) has emerged as a promising route for fabricating complex, patient-specific metallic implants with controlled architectures and tailored mechanical properties. In recent years, significant studies have been reported on the effects of infill patterns (IPs), scan strategies (SSTs), powder recyclability, and process parameters (such as laser power, scanning speed, and energy density) on the microstructure and mechanical performance of PBF-LB-fabricated biocompatible alloys. However, the collective impact of SSTs, IPs, and powder recyclability (which better reflects realistic processing conditions) remains largely unexplored, particularly for biomedical implant applications. In the present work, a Taguchi-based design of experiments (DOE) was employed to systematically investigate the effects of SSTs, IPs, and powder condition (virgin, primary, secondary recycled) on the process stability, microstructural evolution, and mechanical behavior of PBF-LB-fabricated 17-4 precipitate hardened (PH) stainless steel (SS) functional prototypes. Results reveal that among the selected input parameters for PBF-LB, the sample fabricated with virgin (V) powder, rectangular alternate (RA) as SST, and solid (SD) as IP exhibited the highest peak load of 16.04 kN. In comparison, the primary recycled (PR) powder sample, with stripe alternate (SA) as SST and Weaire-Phelan (WP) as IP, exhibited the lowest peak load of 10.04 kN. Overall, the study demonstrates the collective impact of SSTs, IPs, and powder recyclability in tailoring PBF-LB-fabricated 17-4 PH SS functional prototypes for cranio-maxillofacial implant applications.