Binder jetting printed metallic biomaterials

TY - JOUR

T1 - Binder jetting printed metallic biomaterials

AU - Li, Xuan

AU - Shi, Yixuan

AU - Huang, Chengcong

AU - Zhao, Shangyan

AU - Wu, Yuzhi

AU - Song, Yifan

AU - Yang, Zhao

AU - Sun, Yiyang

AU - Li, Peipei

AU - Zhang, Xiangyu

AU - Li, Yageng

AU - Wang, Luning

N1 - Publisher Copyright: © 2025 Elsevier B.V.

PY - 2026/1/5

Y1 - 2026/1/5

N2 - Metallic biomaterials, including traditional inert metals (such as titanium-based, cobalt-based, stainless steel-based alloys) and emerging biodegradable metals (such as iron-, magnesium-, and zinc-based systems), have attracted considerable attention in both research and clinical settings due to their critical roles in treating musculoskeletal diseases and extending human lifespan. One of their key applications lies in the repair of large bone defects, which often require customized implants to replicate the geometry, microarchitecture, and mechanical behavior of native bone. This personalization imposes stringent demands on manufacturing techniques. Binder jetting (BJT), a rapidly advancing powder bed-based additive manufacturing (AM) technology, offers significant advantages including a wide material compatibility, high production efficiency, and the ability to fabricate large and complex parts. Unlike laser or electron beam AM techniques, BJT enables porosity control through post-processing, allowing for tailored structural and functional performance. This review systematically examines the BJT process for metallic biomaterials, focusing on how process variables, such as powder morphology, particle size distribution, binder chemistry, layer thickness, printing speed, binder saturation, and sintering conditions, affect the final properties of printed parts. Design considerations for patient-specific implants are discussed, along with a comprehensive overview of candidate metallic systems, evaluating their mechanical properties, corrosion behavior, and biocompatibility. Finally, the current challenges in using BJT for fabricating biomedical metals, including limitations in resolution, densification, debinding, and sintering deformation, are outlined. Future research directions are also proposed to advance the clinical translation of this promising technology.

AB - Metallic biomaterials, including traditional inert metals (such as titanium-based, cobalt-based, stainless steel-based alloys) and emerging biodegradable metals (such as iron-, magnesium-, and zinc-based systems), have attracted considerable attention in both research and clinical settings due to their critical roles in treating musculoskeletal diseases and extending human lifespan. One of their key applications lies in the repair of large bone defects, which often require customized implants to replicate the geometry, microarchitecture, and mechanical behavior of native bone. This personalization imposes stringent demands on manufacturing techniques. Binder jetting (BJT), a rapidly advancing powder bed-based additive manufacturing (AM) technology, offers significant advantages including a wide material compatibility, high production efficiency, and the ability to fabricate large and complex parts. Unlike laser or electron beam AM techniques, BJT enables porosity control through post-processing, allowing for tailored structural and functional performance. This review systematically examines the BJT process for metallic biomaterials, focusing on how process variables, such as powder morphology, particle size distribution, binder chemistry, layer thickness, printing speed, binder saturation, and sintering conditions, affect the final properties of printed parts. Design considerations for patient-specific implants are discussed, along with a comprehensive overview of candidate metallic systems, evaluating their mechanical properties, corrosion behavior, and biocompatibility. Finally, the current challenges in using BJT for fabricating biomedical metals, including limitations in resolution, densification, debinding, and sintering deformation, are outlined. Future research directions are also proposed to advance the clinical translation of this promising technology.

KW - Binder jetting

KW - Biomaterial

KW - Mechanical property

KW - Metal

KW - Structural design

UR - https://www.scopus.com/pages/publications/105024905000

U2 - 10.1016/j.addma.2025.105045

DO - 10.1016/j.addma.2025.105045

M3 - Review article

AN - SCOPUS:105024905000

SN - 2214-8604

VL - 115

JO - Additive Manufacturing

JF - Additive Manufacturing

M1 - 105045

ER -