In the Spanish research project ATILA, a consortium led by AIDIMME, the foundation of the University Hospital of Valencia (FIHGUV/BTELab), the University of Salamanca (ALF USAL), and OEM Meltio demonstrates that wire-based laser DED (DED-LB/M) is suitable for orthopedic implants made of Ti-6Al-4V ELI. For the first time, welding wire is used instead of powder, reducing waste and simplifying operation. The focus was on three components with regulatory relevance: an acetabular cup, a tibial plateau, and the femoral component for knee prostheses; in-vitro and in-vivo studies are underway.
In the prototype setup at AIDIMME, test specimens were extracted from a printed solid block by wire EDM, machined, and tested according to ASTM E8/E8M. According to the project, the results meet the requirements for tensile strength, elastic modulus, and elongation per ASTM F3001-14, ASTM F136-2021, and UNE EN ISO 5832-3:2022; no additional heat treatments are required. Metallography revealed a martensitic microstructure: acicular α′ phases in a β matrix due to rapid cooling above the β-transus temperature. Of particular importance is the finding that the process does not form an alpha-case layer, which would reduce fatigue strength and is not permitted by standards.
On the process side, the Meltio system combines wire feed with laser energy, enabling part build-up without powder handling. Beyond material efficiency, the approach also targets clean surface chemistry as a basis for osseointegration.
“Machined titanium surfaces do not promote osseointegration and can cause the implant to loosen. Therefore, they must be modified to improve their geometry, roughness, and chemical properties in order to accelerate osseointegration through better protein adsorption and cell growth. The composition, roughness, and hydrophobicity of the surface are essential factors in this process,” says Jenny Zambrano, spokesperson for the ATILA Research Project and researcher at AIDIMME in Valencia.
ATILA views wire-based metal 3D printing as a complement to established methods in medical technology. If the laboratory results can be transferred into robust manufacturing routes with surface modification and a documented process chain, near-patient variant production and reproducible quality for titanium implants could become achievable. Upcoming biological tests and the scaling of process monitoring will determine the path to approval.
Subscribe to our Newsletter
3DPresso is a weekly newsletter that links to the most exciting global stories from the 3D printing and additive manufacturing industry.
