Customizable AZ31 Magnesium Foams: Combining 3D Printing and Investment Casting for Optimized Pore Structures

This study presents the development of AZ31 Mg scaffolds featuring customized internal porosity, designed to emulate the morphology and elastic modulus of human bone. The fabrication process integrated additive manufacturing and investment precision casting to create scaffolds with the desired diamond lattice structure. Emphasis was placed on maintaining the architectural accuracy of the design, employing methods such as micro-computed tomography (µCT) to evaluate dimensional discrepancies. Factors that could impact surface quality and dimensional parameters of the resulting Mg scaffold were examined. Optical examination, chemical composition analysis, and mechanical testing were conducted to characterize the Mg foams. Our diamond lattice structure achieved porosities of 77.9% to 83.4%, aligning with trabecular bone porosity ranges, particularly mandibular condylar bone (72.6–87.4%). Mechanical properties (E = 1.6 ± 0.4 GPa) closely resembled human bone characteristics (0.1–5.0 GPa). This research proposes a predesigned, porous, biodegradable alternative for bone replacement, potentially reducing complications associated with stress shielding.