Magnesium-based materials are used primarily in developing lightweight structures owing to their lower density. Further, being biocompatible they offer potential for use as bioresorbable materials for degradable bone replacement implants. The design and manufacture of complex shaped components made of magnesium with good quality are in high demand in the automotive, aerospace, and biomedical areas. Selective laser melting (SLM) is becoming a powerful additive manufacturing technology, enabling the manufacture of customized, complex metallic designs. This article reviews the recent progress in the SLM of magnesium based materials. Effects of SLM process parameters and powder properties on the processing and densification of the magnesium alloys are discussed in detail. The microstructure and metallurgical defects encountered in the SLM processed parts are described. Applications of SLM for potential biomedical applications in magnesium alloys are also addressed. Finally, the paper summarizes the findings from this review together with some proposed future challenges for advancing the knowledge in the SLM processing of magnesium alloy powders.

Low volume fraction silica nanoparticulate-containing magnesium composites targeting structural and biomedical applications were synthesized using the blend–press–sinter powder metallurgy technique followed by hot extrusion, and subsequently characterized for their microstructural, mechanical and damping properties. The results of microstructural characterization revealed a maximum ∼32% reduction in grain size with 2 vol.% addition of SiO₂ nanoparticulates. The compressive properties of pure magnesium increased with the addition of SiO₂ nanoparticulates with Mg-2 vol.% SiO₂ nanocomposite exhibiting the maximum 0.2% compressive yield strength and compressive fracture strain. The addition of SiO₂ nanoparticulates enhanced the damping characteristics of pure magnesium with Mg-2 vol.% SiO₂ nanocomposite exhibiting the maximum damping capacity and damping loss rate with a minimum change in elastic modulus which is favorable when targeting magnesium for biomedical applications. An attempt has also been made in this study to compare the biomechanical properties of synthesized Mg–SiO₂ nanocomposites with those of natural bone.