The electron beam melting (EBM) method is a rapid prototyping technique that is adopted for artificially fabricating arbitrarily shaped materials ranging from non-porous materials to porous materials. Materials are produced in crosssectional layers using a three-dimensional (3D) computer model. 1,2) Even when metal powder is utilized as a starting material, the use of an electron beam as a heat source for melting the powder facilitates rapid fabrication of laminated structures layer by layer. The use of an electron beam also facilitates control of the pore size, shape, distribution, and porosity during the fabrication of porous materials. Furthermore, since it is possible to fabricate materials directly from metal powder without using a binder, the EBM method is extremely effective for fabricating biological implant metals.3) Therefore, it is possible to fabricate porous metal implants with various 3D morphologies more precisely using this method than using the general melting process, which depends on spontaneous pore formation. Apparent Young's modulus of porous materials can be controlled by varying the configuration of their porous body. By using the EBM method, bone-substitute implants can be developed while preventing the stress-shielding effects arising from the differences between the elastic modulus of the implant metal (e.g., 110 GPa for a Ti-6mass%Al-4mass%V alloy) and that of living bone (e.g., 15-30 GPa in the longitudinal direction of the cortical bone).Bone has a hierarchical structure, and hence the mechanical property is controlled at various scales. Bone contains water, minor proteins, and cells, but its main components are type I collagen and fine crystals of biological apatite (BAp); the combination of these two components provides both strength and flexibility to bone. BAp has a hexagonal ionic crystal with strong anisotropic arrangement of ions, and its c-axis direction is consistent, 4) to a certain degree, with the direction in which the collagen fiber arrranges.
5)These facts indicate that the formation of the texture from the BAp/collagen composite in bone tissue is extremely important for defining basic bone function, including the mechanical function.6) An assessment carried out by microbeam X-ray diffraction revealed that the BAp c-axis orientation of bone depends on the bone shape, site, and in vivo stress distribution.
7)In the case of extensive bone defects due to diseases or bone damage due to accidents, bone function can be regained by replacement using grafting implants or regenerative techniques. New cylindrical bone implants containing elongated pores interconnected as open pores were fabricated by an electron beam melting (EBM) method using Ti-6mass%Al-4mass%V ELI powder (mean particle diameter, 65 mm). New bone formation in the elongated pores of the implant and preferential arrangement of biological apatite c-axis were confirmed along the long bone axis by microbeam X-ray diffraction. Bone mass and preferential degree of biological apatite c-axis, which were considered a b...