In this research, the main purpose was to study the applicability of a machining method on microscale medical-equipment manufacturing. The characteristics of wire electrochemical micromachining (WECMM) against NiTi 50-50 wire was investigated. The study utilized a tungsten wire 0.03 mm in diameter as an electrode to cut a fine slot into the nickel–titanium wire. In order to reach a high-precision WECMM finish, an ultrashort pulse power generator was used as a power source to minimize the stray current effect, thus improving the machining accuracy. During the process, various machining parameters were tested for their effects on machining characteristics. In addition, ultrasonic-vibration-aided WECMM was investigated to determine whether it benefited the machining characteristics. The experiment’s results showed that under such an experiment setting, microslots can be successfully manufactured. Furthermore, with the advance adjustment of experimental parameters, the machining accuracy was improved. Finally, a fine slot was manufactured under the optimum experiment parameters and aided by ultrasonic vibration.

The use of additive manufactured (AM) titanium-based materials has increased substantially for medical implants and aerospace components. However, the inferior surface roughness of additive manufactured products affects the outward appearance and reduces performance. This study determines whether activation treatment prior to electropolishing produces a better surface. Oxalic acid (OA) is used as a pre-activator using different experimental conditions and the surface roughness is reduced by electropolishing with an electrolyte of perchloric acid and glacial acetic acid. The SEM surface morphology, mechanical properties, phase transformation and electrochemical properties are measured to determine the effect of different degrees of roughness on the surface. The results show that the surface roughness of AM titanium-based samples decreases from 8.47 µm to 1.09 µm after activation using OA as a pre-treatment for electropolishing. After electropolishing using optimal parameters, the hardness and resistance to corrosion resistance are increased.

Titanium alloys are widely used in the aerospace, automotive, chemical, and biomedical industries due to their excellent corrosion resistance, mechanical properties, and biocompatibility. However, the surface properties of titanium alloys are often insufficient to meet the increasingly complex requirements of certain applications. Therefore, enhancing the surface performance of titanium alloys in physiological environments has become a key focus of research. In this study, a porous oxide layer was generated on the surface of a titanium substrate through micro-arc oxidation (MAO). This layer served as an intermediate layer for a subsequently deposited polyurethane (PU) coating, providing a strong foundation for adhesion. The high porosity of the MAO layer not only facilitated the adhesion of the PU coating but also protected the titanium alloy, further enhancing its corrosion resistance. The surface microstructure after MAO treatment and the morphological changes after application of the PU coating were characterized using scanning electron microscopy. The PU layer uniformly covered the surface of the MAO layer, significantly improving the smoothness and uniformity of the surface. The increase in surface smoothness due to the PU coating on top of the MAO layer was verified through white light interferometry. Additionally, surface hydrophobicity was assessed through water contact angle measurements. The PU layer over the MAO coating significantly enhanced the hydrophobicity of the titanium alloy’s surface, which is crucial for reducing biofouling and improving the effectiveness of biomedical implants. Finally, electrochemical analysis was conducted to study the corrosion resistance of the titanium alloy after MAO and PU treatment. The titanium alloy with an MAO–PU composite coating exhibited the highest corrosion resistance. The findings revealed that the combination of the MAO layer and PU coating provides an excellent multifunctional protective layer for titanium alloys, not only enhancing their durability but also their ability to adapt to physiological and harsh environments.