Multiphysics Design and Additive Manufacturing of Metallic Metamaterial Porous Scaffolds for Bone Repair

Applying metamaterial design concepts to metallic bone scaffolds provides a novel approach for bone repair and regeneration by integrating architected structural design with metallic biomaterials. The structural foundation of these scaffolds lies in tailorable porous architectures characterized by interconnected networks with specific pore sizes, porosities, and topologies. In these engineered scaffolds, the solid metallic framework determines the mechanical load-bearing capability, while the interconnected pore network regulates mass transport and the local biological microenvironment, thereby influencing cell fate. Today, computational design and metal additive manufacturing enable the coordinated optimization of mechanical and biological requirements through multiphysics coupling, while appropriate post-processing strategies can mitigate manufacturing-induced defects and geometrical deviations, bringing the actual scaffold performance closer to its intended design. Animal studies further evaluate the biological response, tissue integration, and bone-regeneration performance of these scaffolds. Therefore, by combining metamaterial design with pore-structure regulation, additive manufacturing, and post-processing, high-performance metallic bone scaffolds with mechanical compatibility, efficient mass transport, and enhanced bone-regeneration capability can be realized.