Mechanical performance and corrosion resistance predictions of 3D printed porous meta scaffolds

This study presents an integrated approach to evaluating the mechanical behavior and long-term durability of metallic lattice scaffolds by combining experimental testing with predictive modeling of corrosion-induced degradation. Three Ti6Al4V lattice geometries, including Diamond, Voronoi, and Lidinoid, were fabricated using SLM and tested under uniaxial compression to evaluate their stiffness, strength, and post-failure behavior. While the Diamond geometry exhibited superior initial strength and modulus, the Lidinoid structure demonstrated enhanced strength in the plateau region, resulting in greater energy absorption. To extend the assessment beyond initial mechanical response, we developed an analytical model that integrates uniform and pitting corrosion mechanisms into the Gibson–Ashby framework for cellular solids. The model relates time-dependent changes in pore geometry to evolving mechanical properties through corrosion kinetics. Validation against published data on degrading porous magnesium scaffolds demonstrated reasonable agreement, confirming the model's capability in predicting long-term structural performance. By enabling early-stage estimation of scaffold durability, ranging from stable titanium to rapidly degrading magnesium, the framework provides a computationally efficient alternative to repeated corrosion experiments and finite element simulations. This unified approach supports the rational design of both biodegradable and long-term implants by balancing mechanical performance with degradation rates, ultimately enhancing clinical outcomes in bone tissue engineering. • Mechanical behavior of three Ti6Al4V lattice morphologies was experimentally evaluated. • A unified analytical model predicts corrosion-induced degradation in porous metals. • Corrosion kinetics were linked to mechanical loss via Gibson-Ashby model.