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 -