Qualification of an Additive-Subtractive Process for Medical Implants Via Powder Bed Fusion of Commercially Pure Titanium Using a Laser Beam
 
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1
Institute for Machine Tools and Factory Management, Technische Universität Berlin, Germany
 
2
IPK, Fraunhofer Institute for Production Systems and Design Technology, Germany
 
3
Department of Prosthodontics, Geriatric Dentistry and Craniomandibular Disorders, Charité - Universitätsmedizin Berlin,, Germany
 
 
Submission date: 2026-02-26
 
 
Final revision date: 2026-04-30
 
 
Acceptance date: 2026-05-13
 
 
Online publication date: 2026-06-02
 
 
Corresponding author
Malek Abu-Gharbieh   

Institute for Machine Tools and Factory Management, Technische Universität Berlin, Pascalstraße, 10587, Berlin, Germany
 
 
 
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ABSTRACT
Additive manufacturing with powder bed fusion of metals using a laser beam (PBF-LB/M) enables the manufacturing of complex medical implant geometries, such as patient-specific dental implants that replicate the shape of natural tooth roots. Such geometries may support improved osseointegration in the jawbone. This study investigates commercially pure titanium grade 2 (TiGd2) produced by PBF-LB/M as the basis of an additive-subtractive process for medical implants. Specimens were manufactured in different build orientations (BO) to assess material and surface properties. Micro computed tomography indicated a low internal defect density. Tensile testing showed BO dependent anisotropy, whereas compression testing showed no pronounced anisotropy. Across all BO, mean values were ultimate tensile strength RM = 772 MPa, elongation at break A = 24.4 %, and compressive yield strength R_dp = 746 MPa. Surface post processing enabled adjustment of roughness, with Ra decreasing from Ra_as = 6.3 µm in the as built state to Ra_pb = 5.1 µm after particle blasting, Ra_et = 3.6 µm after acid etching, and Ra_df = 0.36 µm after disc finishing. Overall, the results confirm the potential of PBF-LB/M processed TiGd2 for additive subtractive manufacturing of medical implants.
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