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<p>Porous bone scaffolds have attracted considerable interest for the design and manufacture of load-bearing bone substitutes, owing to their structural design flexibility and tunable mechanical properties. In this work, four porous lattice scaffolds—face-centered cubic (FCC), body-centered cubic (BCC), and two composite architectures—were designed and fabricated from 316L stainless steel powder using laser powder bed fusion (L-PBF). Under uniform processing conditions, the residual stress, surface roughness, and compressive strength of different structures were systematically evaluated by means of finite element simulation, L-PBF manufacturing, X-ray diffraction (XRD), and scanning electron microscopy (SEM). A hierarchical design strategy was proposed to balance surface quality with load-bearing capacity. The results show that the BCC–FCC structure with an FCC outer layer exhibited the lowest surface roughness (Ra ≈ 11.4&#xa0;μm), whereas the FCC–BCC structure achieved the highest ultimate strength (≈416.6&#xa0;MPa). Moreover, the composite structures displayed a more uniform residual stress distribution, in agreement with the simulation predictions. This study demonstrates that the “FCC outer layer + BCC core” design can simultaneously improve both surface quality and mechanical performance without modifying the process parameters, offering a novel approach for the precision design and clinical application of porous metal scaffolds.</p>

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Laser Powder Bed Fusion of FCC–BCC Composite Lattice Porous Scaffolds: Synergistic Optimization of Residual Stress, Surface Quality, and Mechanical Properties

  • 期刊论文

  • 发表日期：

    2026年1月30日

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  • Haozhe Cheng,
  • Shubo Xu,
  • Xinyi Zhang,
  • Xue Yang,
  • Hailong Ma,
  • Renhui Liu,
  • Jianing Li

摘要

Porous bone scaffolds have attracted considerable interest for the design and manufacture of load-bearing bone substitutes, owing to their structural design flexibility and tunable mechanical properties. In this work, four porous lattice scaffolds—face-centered cubic (FCC), body-centered cubic (BCC), and two composite architectures—were designed and fabricated from 316L stainless steel powder using laser powder bed fusion (L-PBF). Under uniform processing conditions, the residual stress, surface roughness, and compressive strength of different structures were systematically evaluated by means of finite element simulation, L-PBF manufacturing, X-ray diffraction (XRD), and scanning electron microscopy (SEM). A hierarchical design strategy was proposed to balance surface quality with load-bearing capacity. The results show that the BCC–FCC structure with an FCC outer layer exhibited the lowest surface roughness (Ra ≈ 11.4 μm), whereas the FCC–BCC structure achieved the highest ultimate strength (≈416.6 MPa). Moreover, the composite structures displayed a more uniform residual stress distribution, in agreement with the simulation predictions. This study demonstrates that the “FCC outer layer + BCC core” design can simultaneously improve both surface quality and mechanical performance without modifying the process parameters, offering a novel approach for the precision design and clinical application of porous metal scaffolds.