Selective Laser Melting (SLM), a method used in the nuclear, space and racing industries, allows the creation of customized titanium alloy scaffolds with highly defined external shape and internal structure (pore size) using rapid prototyping as supporting external structures within which bone tissue can grow. Human osteoblasts were cultured on SLM-produced 3D titanium alloy (Ti6Al4V) mesh scaffolds to demonstrate biocompatibility using Scanning Electron Microscopy (SEM) and fluorescence microscopy after cell vitality staining. The occlusion of pores of different widths (0.45 - 1.2 mm) by osteoblasts was evaluated. SEM investigations showed osteoblasts with well-spread morphology and multiple contact points. Cell vitality staining confirmed osteoblast vitality. 1 week after seeding, only 0.45 mm pores showed any occlusion by osteoblasts (21%). At 3 weeks the occlusion of 0.45 mm, 0.5 mm, 0.55 mm, 0.6 mm and 0.7 mm pores was 79%, 67%, 67%, 44% and 10%, respectively. At 6 weeks the occlusion of 0.45 mm and 0.5 mm pores had risen to 100%, but no increase was observed for 0.55 mm, 0.6 mm and 0.7 mm pores. No pore occlusion was observed on pores of width 0.9 – 1.2 mm. In summary, the scaffolds are biocompatible and pore size influences pore overgrowth.

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