MoldJet sinter-based additive manufactured 316L SS: achieving isotropic microstructure, enhanced mechanical properties, corrosion resistance, and biocompatibility

• MoldJet produces simple-geometry 316 L parts with uniform microstructure and ∼ 99.9% relative density. • Ultimate tensile strengths of 520–570 MPa and elongations of 60–80% across all build orientations. • Corrosion resistance surpasses other AM techniques due to robust passivation. • In vitro assays confirm excellent biocompatibility and osteogenic potential. • MoldJet offers powder-free, scalable fabrication for complex biomedical components. Designing patient-specific metallic implants demands manufacturing routes that combine high density, isotropic mechanical response, corrosion resistance and biocompatibility. This study evaluates Tritone MoldJet, a powder-free, sinter-based additive manufacturing (AM) process, as a route for 316 L stainless steel. We ask whether MoldJet can deliver process-structure–property combinations comparable to or better than established AM and conventional routes used in implant design. 316 L test bulk and lattice demonstrators were fabricated by MoldJet. Bulk samples were characterized in terms of density and pore morphology (X-µCT), microstructure (XRD, SEM/EDS), tensile and hardness properties, and corrosion behavior in phosphate-buffered saline (immersion and electrochemistry). Lattices were used for in vitro osteoblast assays. The resulting property set of the dense samples was benchmarked against wrought, MIM, PBF, DED, BJT and LMM 316 L using materials-property charts. MoldJet 10 × 10 × 10 mm cubes reached 99.9% relative density with predominantly spherical pores (∼70 µm) and a homogeneous equiaxed austenitic microstructure. Tensile tests showed near-isotropic behavior with ultimate tensile strengths of 520–570 MPa and elongations of 60–80%, within the upper range of wrought and MIM 316 L. Corrosion tests indicated low corrosion currents and stable passive films, comparable to or better than literature data for other 316 L routes. Osteoblasts remained viable, adhered and deposited mineralized matrix on MoldJet 316 L scaffolds. Together, these results provide an initial process-microstructure-property dataset for MoldJet 316 L within the tested conditions and dense geometries, offering reference metrics for benchmarking against established 316 L manufacturing routes in implant‑relevant contexts.