Volumetric Infiltration of Brushite and Monetite Cements into Laser Powder Bed Fusion Ti-6Al-4V Lattices: A Feasibility Study of Lattice Geometry and Cement Formulation

Craniofacial defects following maxillectomy present major reconstructive challenges, and although autologous vascularized free flaps remain standard, they carry donor-site morbidity and surgical burden. Additive manufacturing and bioactive coatings enable hybrid metallic–ceramic constructs; however, whether a bioactive phase can be delivered throughout the internal volume of an architected metal lattice, rather than only onto its surface, remains poorly characterized. In this feasibility study, laser powder bed fusion (LPBF) was used to fabricate porous Ti-6Al-4V lattices (5 mm diameter) in two geometries (octagon and grid) at nominal strut spacings of 500 and 1000 µm. Resorbable dicalcium phosphate cements of β-tricalcium phosphate and monocalcium phosphate monohydrate were infiltrated at two powder-to-liquid ratios (P/L 0.5 and 0.75) to form brushite, then thermally dehydrated to monetite. X-ray diffraction confirmed phase purity and brushite-to-monetite conversion. Micro-computed tomography showed infiltration to the lattice core, with calcium phosphates across both geometries and pore sizes; both workable formulations were compatible with the infiltration procedure. These results establish preliminary processing conditions for volumetric biofunctionalization of porous titanium and provide a defined basis for subsequent geometric, mechanical, adhesion, and biological evaluation.