Tailored Pore Architectures in Ti6Al4V Bone Scaffolds for Tunable Permeability and Mechanical Performance

To achieve multifunctionalities such as nutrient transport, cellular activities, and load‐bearing while avoiding stress shielding, bone tissue engineering scaffolds must exhibit consistent permeability and mechanical properties comparable to those of human bones. Here, filament‐rotated, filament‐shifted, gradient, and conventional Ti6Al4V scaffolds are designed and fabricated using direct ink writing. These scaffolds exhibit high‐precision and interconnective pores and simultaneously match the permeability and elastic modulus with human trabeculae. The impact of internal pore architecture on the permeability and mechanical properties of the scaffolds is investigated systematically through experimental and numerical methods. Compared to conventional scaffolds, alterations in pore structure result in decreased permeability and elastic modulus. The influence of porosity on scaffold permeability outweighs that of pore architecture. The shifted 100% scaffold exhibits a more uniform and symmetrical distribution of wall shear stress, which may promote cell adhesion and proliferation. By tuning the porosity with diverse pore architectures, a wide range of permeability (e.g., experimental values of 1.12 × 10 −10 to 2.95 × 10 −10 m 2 ) and mechanical property (e.g., experimental elastic moduli of 1.0–5.7 GPa) can be achieved. A hierarchical, goal‐oriented selection framework is proposed to guide the internal pore structural design of patient‐specific scaffolds across various anatomical sites.