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Process–Structure–Property Relationships in Selective Laser Melting of Porosity Graded Gyroids

Selective laser melting (SLM) can be used to tailor both the geometry and mechanical properties of lattice structures to match bone properties. In this work, a process–structure–property (PSP) relationship for Ti6AL4V porosity graded gyroids (PGGs) structures was developed. A design of experiment approach was used to test the significance and contribution of different process parameters on microstructure, morphology, and mechanical properties. Process maps to predict the morphology errors at specific laser power and scan speed were developed. Moreover, the mechanical properties of radially PGGs with a relative density of 25% are evaluated using different SLM process parameters. The results showed that PGGs with different radial gradation designs have mechanical properties that are compatible with bone implants: apparent compressive modulus of 1.4–5.3 GPa and compressive strength 40–154 MPa.