Optimising degradation and mechanical performance of additively manufactured biodegradable Fe–Mn scaffolds using design strategies based on triply periodic minimal surfaces

Additively manufactured lattices based on triply periodic minimal surfaces (TPMS) have attracted significant research interest from the medical industry due to their good mechanical and biomorphic properties. However, most studies have focussed on permanent metallic implants, while very little work has been undertaken on manufacturing biodegradable metal lattices. In this study, the mechanical properties and in vitro corrosion of selective laser melted Fe–35%Mn lattices based on gyroid, diamond and Schwarz primitive unit-cells were comprehensively evaluated to investigate the relationships between lattice type and implant performance. The gyroid-based lattices were the most readily processable scaffold design for controllable porosity and matching the CAD design. Mechanical properties were influenced by lattice geometry and pore volume. The Schwarz lattices were stronger and stiffer than other designs with the 42% porosity scaffold exhibiting the highest combination of strength and ductility, while diamond and gyroid based scaffolds had lower strength and stiffness and were more plastically compliant. The corrosion behaviour was strongly influenced by porosity, and moderately influenced by geometry and geometry-porosity interaction. At 60% porosity, the diamond lattice displayed the highest degradation rate due to an inherently high surface area-to-volume ratio. The biodegradable Fe–35Mn porous scaffolds showed a good cytocompatibility to primary human osteoblasts cells. Additive manufacturing of biodegradable Fe–Mn alloys employing TPMS lattice designs is a viable approach to optimise and customise the mechanical properties and degradation response of resorbable implants toward specific clinical applications for hard tissue orthopaedic repair.