FURI | Fall 2025

Fabrication of Neat Porous Bone Implants via Vaporization in Additive Manufacturing

Metal alloys that are commonly used for bone implants have a higher elastic modulus than human bones, which can lead to stress shielding. To avoid this, porous structures are created in the alloy. However, when using typical methods of Laser Powder Bed Fusion (LPBF), it is common to have loose metal powders within the pores, which can be harmful. This research project will attempt to create porous structures by vaporizing the metal and creating a “bubble” that will develop into a pore as the liquid metal around it cools, effectively avoiding the health risks associated with loose metal powders.