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Direct metal deposition (DMD) is a rapid laser-aided deposition method that can be used to manufacture near-net-shape components from their computer aided design (CAD) files. The method can be used to produce fully dense or porous metallic parts. The Ti-6Al-4V alloy is widely used as an implantable material mainly in the application of orthopedic prostheses because of its high strength, low elastic modulus, excellent corrosion resistance, and good biocompatibility. In the present study, Ti-6Al-4V scaffold has been fabricated by DMD technology for patient specific bone tissue engineering. Good geometry control and surface finish have been achieved. The structure and properties of the scaffolds were investigated by X-ray diffraction (XRD), scanning electron microscopy (SEM), transmission electron microscopy (TEM), and tension test. The microstructures of laser-deposited Ti-6Al-4V scaffolds are fine Widmansta¨tten in nature. The tensile and yield strengths of the as-deposited Ti-6Al-4V were 1163 ± 22 and 1105 ± 19 MPa, respectively, which are quite higher than the ASTM limits (896 and 827 MPa) for Ti-6Al-4V implants. However, the ductility of the as-deposited sample was very low (~4 pct), which is well below the ASTM limit (10 pct). After an additional heat treatment (sample annealed at 950°C followed by furnace cooling), both strength (UTS1 045 ± 16, and YS~959 ± 12 MPa) and ductility (~10.5 ± 1 pct) become higher than ASTM limits for medical implants.

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