In the present day, the increment in life expectancy has led to the necessity of developing new biomaterials for the restoration or substitution of damaged organs that have lost their functionalities. Among all the research about biomaterials, this review paper aimed to expose the main possibilities that the sol-gel synthesis method can provide for the fabrication of materials with interest in the biomedical field, more specifically, when this synthesis method is used to improve the biological properties of different magnesium alloys used as biomaterials. The sol-gel method has been widely studied and used to generate ceramic materials for a wide range of purposes during the last fifty years. Focused on biomedical research, the sol-gel synthesis method allows the generation of different kinds of biomaterials with diverse morphologies and a high potential for the biocompatibility improvement of a wide range of materials commonly used in the biomedical field such as metallic implants, as well as for the generation of drug delivery systems or interesting biomaterials for new tissue engineering therapies.

This review explores the advancements in additive manufacturing (AM) of biodegradable iron (Fe) and zinc (Zn) alloys, focusing on their potential for medical implants, particularly in vascular and bone applications. Fe alloys are noted for their superior mechanical properties and biocompatibility but exhibit a slow corrosion rate, limiting their biodegradability. Strategies such as alloying with manganese (Mn) and optimizing microstructure via laser powder bed fusion (LPBF) have been employed to increase Fe’s corrosion rate and mechanical performance. Zn alloys, characterized by moderate biodegradation rates and biocompatible corrosion products, address the limitations of Fe, though their mechanical properties require improvement through alloying and microstructural refinement. LPBF has enabled the fabrication of dense and porous structures for both materials, with energy density optimization playing a critical role in achieving defect-free parts. Fe alloys exhibit higher strength and hardness, while Zn alloys offer better corrosion control and biocompatibility. In vitro and in vivo studies demonstrate promising outcomes for both materials, with Fe alloys excelling in load-bearing applications and Zn alloys in controlled degradation and vascular applications. Despite these advancements, challenges such as localized corrosion, cytotoxicity, and long-term performance require further investigation to fully harness the potential of AM-fabricated Fe and Zn biodegradable implants.

Magnesium AZ31 alloy substrates were coated with different coatings, including sol–gel silica-reinforced with graphene nanoplatelets, sol–gel silica, plasma electrolytic oxidation (PEO), and combinations of them, to improve cytocompatibility and control the corrosion rate. Electrochemical corrosion tests, as well as hydrogen evolution tests, were carried out using Hanks’ solution as the electrolyte to assess the anticorrosion behavior of the different coating systems in a simulated body fluid. Preliminary cytocompatibility assessment of the different coating systems was carried out by measuring the metabolic activity, deoxyribonucleic acid quantification, and the cell growth of premyoblastic C2C12-GFP cell cultures on the surface of the different coating systems. Anticorrosion behavior and cytocompatibility were improved with the application of the different coating systems. The use of combined PEO + SG and PEO + SG/GNP coatings significantly decreased the degradation of the specimens. The monolayer sol–gel coatings, with and without GNPs, presented the best cytocompatibility improvement.

This work expands the processing window of the laser powder bed fusion (LPBF) processing of WE43 magnesium alloy by evaluating laser powers and scanning speeds up to 400 W and 1200 mm/s, and their effect on densification, microstructure, and electrochemical performance. Relative density of 99.9% was achieved for 300 W and 800 mm/s, showing that the use of high laser power is not a limitation for the manufacturing of Mg alloys, as has been usually considered. Microstructural characterisation revealed refined grains and the presence of RE-rich intermetallic particles, while microhardness increased with height due to thermal gradients. Electrochemical testing in 3.5 wt.% NaCl solution, a more aggressive media than those already used, indicated that the corrosion of samples with density values below 99% is conditioned by the porosity; however, above this value, in the WE43, the corrosion evolution is more related to the microstructure of the samples, according to electrochemical evaluation. This study demonstrates the viability of high-energy LPBF processing for WE43, offering optimised mechanical and corrosion properties for biomedical and structural applications.

This review explores the advancements in additive manufacturing (AM) of biodegradable iron (Fe) and zinc (Zn) alloys, focusing on their potential for medical implants, particularly in vascular and bone applications. Fe alloys are noted for their superior mechanical properties and biocompatibility but exhibit a slow corrosion rate, limiting their biodegradability. Strategies such as alloying with manganese (Mn) and optimizing microstructure via Laser Powder Bed Fusion (LPBF) have been employed to increase Fe´s corrosion rate and mechanical performance. Zn alloys, characterized by moderate biodegradation rates and biocompatible corrosion products, address the limitations of Fe, though their mechanical properties require improvement through alloying and microstructural refinement. LPBF has enabled the fabrication of dense and porous structures for both materials, with energy density optimization playing a critical role in achieving defect-free parts. Fe alloys exhibit higher strength and hardness, while Zn alloys offer better corrosion control and biocompatibility. In vitro and in vivo studies demonstrate promising outcomes for both materials, with Fe alloys excelling in load-bearing applications and Zn alloys in controlled degradation and vascular applications. Despite these advancements, challenges such as localized corrosion, cytotoxicity, and long-term performance require further investigation to fully harness the potential of AM-fabricated Fe and Zn biodegradable implants.