Influence of Laser Powder Bed Fusion Parameters on Surface Characteristics and Mechanical Properties of 316L Porous Bone Scaffolds

Through an integrated approach combining finite element numerical simulation with experimental validation, nine parameter sets were designed using orthogonal experimental methodology to systematically investigate the residual stress evolution mechanisms and deformation behavior of porous scaffolds during laser powder bed fusion. The interfacial shear strength was calculated based on comprehensive measurements of surface roughness, microhardness, microstructural characterization, and electrochemical corrosion performance. This study analyzed the effects of different process parameters on the corrosion resistance, surface roughness, residual stress, and interfacial shear strength of porous scaffolds with different structures. Experimental analysis demonstrates that both residual stress and surface roughness exhibit significant positive correlations with energy density, while the interfacial shear strength displays a nonlinear variation pattern characterized by an initial decrease, followed by an increase with rising energy density. The material manifests optimal electrochemical corrosion performance at an energy density of 78.70 J/mm 3 .