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Current intervertebral fusion devices present multiple complication risks such as a lack of fixation, device migration and subsidence. An emerging solution to these problems is the use of additively manufactured lattice structures that are mechanically compliant and permeable to fluids, thus promoting osseointegration and reducing complication risks. Strut-based diamond and sheet-based gyroid lattice configurations having a pore diameter of 750 µm and levels of porosity of 60, 70 and 80% are designed and manufactured from Ti-6Al-4V alloy using laser powder bed fusion. The resulting structures are CT–scanned, compression tested and subjected to fluid permeability evaluation. The stiffness of both structures (1.9–4.8 GPa) is comparable to that of bone, while their mechanical resistance (52–160 MPa) is greater than that of vertebrae (3–6 MPa), thus decreasing the risks of wither bone or implant failure. The fluid permeability (5–57 × 10 −9 m 2 ) and surface-to-volume ratios (~3) of both lattice structures are close to those of vertebrae. This study shows that both types of lattice structures can be produced to suit the application specifications within certain limits imposed by physical and equipment-related constraints, providing potential solutions for reducing the complication rate of spinal devices by offering a better fixation through osseointegration.

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