Implant failure is a common problem in orthopedic applications, which causes pain and stress for patients, prolonged antibiotic therapy, increased time and cost of hospitalization, and revision surgery. Selecting the optimum porous structure, manufacturing process and surface modification approach is crucial to reduce the rate of implant failure. The design of porous structures in orthopedic implants plays an important role in vascularization, diffusion of nutrients, and in the relationship between implants and osteoblasts. Common techniques for porous design are computer aided design (CAD), image based design, implicit surface design, and topology optimization. Metal-based additive manufacturing methods such as electron beam melting (EBM), selective laser melting (SLM) and selective laser sintering (SLS) have been extensively developed for fabrication of porous structures on Titanium. Several chemical surface modification methods are used, such as acid etching, anodization, and coatings, to improve mechanical properties, biocompatibility, increase surface roughness, and to promote osseointegration and bone regrowth. This paper reviews the design and manufacturing of porous implant material via additive manufacturing techniques, as well as recent advances in surface modification, to achieve biocompatible surfaces. The outcome of this research will provide an effective strategy for manufacturing, and surface modification of titanium orthopedic implants.
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