The reconstruction of segmental bone defects requires patient-specific scaffolds that combine mechanical safety, biological functionality, and rapid manufacturing. We converted CT-derived mandibular geometry into a functionally graded Ti-6Al-4V lattice and optimised porosity, screw layout, and strut thickness through a cyber-physical loop that joins high-fidelity FEM, millisecond ANN, and a BN for uncertainty quantification. Fifteen candidate scaffolds were fabricated by direct metal laser sintering and hot isostatic pressing and were mechanically tested. FEM predicted stress and stiffness with 98% accuracy; the ANN reproduced these outputs with 94% fidelity while evaluating 10,000 designs in real time, and the BN limited failure probability to <3% under worst-case loads. The selected 55–65% porosity design reduced titanium use by 15%, shortened development time by 25% and raised multi-objective optimisation efficiency by 20% relative to a solid-plate baseline, while resisting a 600 N bite with a peak von Mises stress of 225 MPa and micromotion < 150 µm. Integrating physics-based simulation, AI speed, and probabilistic rigour yields a validated, additively manufactured scaffold that meets surgical timelines and biomechanical requirements, offering a transferable blueprint for functional scaffolds in bone and joint surgery.

This study investigates the fabrication, characterization, and computational analysis of a Ti6Al4V porous scaffold for bone tissue engineering (BTE). The main objective is to address the stress-shielding effect caused by the mismatch in the mechanical properties between the scaffold and surrounding bone. An octet-truss architecture was considered to design a highly porous scaffold (with 80.5% porosity) and fabricated using selective laser melting (SLM). The scaffold was then treated with post-processing chemical etching in oxalic acid to remove surface defects and tailor topography. Scanning electron microscopy (SEM) and X-ray diffraction (XRD) revealed that etching effectively removed adhered unmelted powder particles and created a distinct micro-textured strut surface (with increased roughness) that is conducive to osseointegration. The etching process also uniformly thinned down the struts and resulted in 10% mass loss. A compression test gave the scaffold’s compliance-corrected elastic moduli of 4.54 ± 0.18 GPa (pre-etching) and 3.53 ± 0.06 GPa (post-etching). These values closely match with the stiffness of human trabecular bone reported in the literature. The experimental modulus results were validated with a finite element model that predicted 4.188 GPa, which agrees well with the experiment. Furthermore, computational fluid dynamic simulations evaluated a permeability of 8 × 10^–9 m², consistent with transport in bone-like structures.

This study focuses on surface modification of aluminum alloys (Al–Si) with high silicon content using plasma electrolytic oxidation (PEO). The influence of Al₂O₃ and SiO₂ particles, introduced both separately and in combination, into a sodium aluminate-based electrolyte during high-frequency treatment (2000 Hz). Examination of surface and cross-sections using a scanning electron microscope SEM showed an increase in the compactness of the coating when Al₂O₃ particles were introduced. The addition of SiO₂ particles tended to promote a smoother surface and a slight reduction in the porosity and defect density. However, when these particles are added together, especially at high concentrations, an increase in structural defects and crack formation is observed. X-ray diffraction analysis revealed that the γ-Al₂O₃ phase was present in all coatings. In the samples with Al₂O₃ addition, the α-Al₂O₃ diffraction signal became stronger compared with the other coatings. Tribological tests revealed that the addition of Al₂O₃ particles significantly improved wear resistance, while the introduction of SiO₂ particles contributed to the stabilization of the friction coefficient. Thus, Al₂O₃ particles were the most effective in enhancing the mechanical properties of the coating.