Transforming biofabrication with powder bed fusion additive manufacturing technology: from personalized to multimaterial solutions

Additive manufacturing (AM) is emerging as a transformative technology in the biomedical field. Among various AM technologies, powder bed fusion (PBF) stands out as a versatile manufacturing method with the ability to incorporate a diverse range of materials. This specialty allows for its applications across multiple fields, ranging from the production of microcomponents and complex biocompatible structures to the manufacturing of aerospace parts. Here, we overview the evolution of AM technology in general along with its diverse applications, with a particular focus on recent advancements in PBF as a highly successful emerging technology for biomedical applications. The paper explores the state-of-the-art techniques employed in the fabrication of biomedical products via PBF showcasing its ability to create detailed and intricate porous, and tailor-made structures using various biocompatible materials. We discuss the unique attributes of PBF that facilitate the fabrication of complex porous structures, enhance biological integration, and enable the development of patient-specific medical devices, implants, drug delivery systems and pharmaceutics. The discussion is further extended to offer insights into the ongoing developments in clinical trials of the PBF manufactured biomedical products. Special attention is given to the emerging field of multi-material AM technology in PBF. This concise review offers a comprehensive outlook on the current status and promising future avenues of PBF in the domain of biomedical research.