Optimisation of 3D Printing Parameters and Surface Modification for Porous Gyroid Structures in Beta Titanium Alloy Ti25Nb4Ta8Sn

In recent years, 3D printing has become a key technology for producing intricate geometries with high precision. Beta titanium alloys (β-Ti), due to their excellent combination of strength, ductility, low elastic modulus, and biocompatibility, are widely used in the aerospace and medical industries. However, the unique microstructure formed during additive manufacturing characterised by porosity, residual stress, and anisotropy can significantly influence the mechanical performance and durability of these materials. This study examines how different printing parameters affect porosity, dimensional stability, and mechanical properties in the β-Ti alloy Ti25Nb4Ta8Sn. The investigation focuses on thin-walled samples and gyroid structures, which represent model geometries for porous biomedical components. These structures, defined by a periodic network of interconnected channels, provide a useful platform for studying the relationship between geometry and mechanical response. In addition, the effects of surface etching on the morphology and compressive behaviour of printed gyroid structures were evaluated. Compression testing was used to determine how etching alters load-bearing performance and to identify correlations between surface modification and mechanical response. The combined analysis enables optimisation of both printing and post-processing parameters for advanced biomedical applications.