The Ti6Al4V alloy is widely used in orthopedic implants due to its excellent mechanical properties and biocompatibility. However, traditional manufacturing techniques are unable to fabricate complex geometrical shapes with tailored properties. This leads to premature failure due to wear, corrosion, and poor osseointegration. Recent advancements in laser-based additive manufacturing, particularly in direct metal laser sintering (DMLS), offer new opportunities to produce Ti6Al4V implants with tailored microstructures, mechanical properties, and biocompatibility. However, wear, corrosion, and cell viability behavior, required for evaluating the biomedical applicability of Ti6Al4V alloy produced through the DMLS route have not been reported. The present study fulfills this gap in the literature. Micro structural study revealed that DMLS-produced Ti6Al4V has a porous and fine grain structure (with mostly α′ phase) without any crack formation due to the controlled parameters during DMLS. Corrosion tests were conducted in simulated body fluid as an electrolytic media, while fibroblast cell lines were used to evaluate the cell viability. Compared to the conventional cast product, DMLS-produced Ti6Al4V alloy exhibited significantly higher porosity (4.8 times), scratch resistance (23.25%), wear resistance (11.53%), corrosion resistance (16.56%), and cell growth. (4.37%), thus making it a more suitable alloy for implants.
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