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Metal additive manufacturing is a powerful tool for providing the desired functional performance through a three-dimensional (3D) structural design. Among the material functions, anisotropic mechanical properties are indispensable for enabling the capabilities of structural materials for living tissues. For biomedical materials to replace bone function, it is necessary to provide an anisotropic mechanical property that mimics that of bones. For desired control of the mechanical performance of the materials, we propose a novel 3D puzzle structure with cube-shaped parts comprising 27 (3 × 3 × 3) unit compartments. We designed and fabricated a Co–Cr–Mo composite structure through spatial control of the positional arrangement of powder/solid parts using the laser powder bed fusion (L-PBF) method. The mechanical function of the fabricated structure can be predicted using the rule of mixtures based on the arrangement pattern of each part. The solid parts in the cubic structure were obtained by melting and solidifying the metal powder with a laser, while the powder parts were obtained through the remaining nonmelted powders inside the structure. This is the first report to achieve an innovative material design that can provide an anisotropic Young’s modulus by arranging the powder and solid parts using additive manufacturing technology.

Although three-dimensional (3D) bioprinting techniques enable the construction of various living tissues and organs, the generation of bone-like oriented microstructures with anisotropic texture remains a challenge. Inside the mineralized bone matrix, osteocytes play mechanosensing roles in an ordered manner with a well-developed lacunar-canaliculi system. Therefore, control of cellular arrangement and dendritic processes is indispensable for construction of artificially controlled 3D bone-mimetic architecture. Herein, we propose an innovative methodology to induce controlled arrangement of osteocyte dendritic processes using the laminated layer method of oriented collagen sheets, combined with a custom-made fluid flow stimuli system. Osteocyte dendritic processes showed elongation depending on the competitive directional relationship between flow and substrate. To the best of our knowledge, this study is the first to report the successful construction of the anisotropic bone-mimetic microstructure and further demonstrate that the dendritic process formation in osteocytes can be controlled with selective fluid flow stimuli, specifically by regulating focal adhesion. Our results demonstrate how osteocytes adapt to mechanical stimuli by optimizing the anisotropic maturation of dendritic cell processes.

In this study, a Ti–6Al–4V alloy composite with uniaxial anisotropy and a hierarchical structure is fabricated using electron beam powder bed fusion, one of the additive manufacturing techniques that enable arbitrary fabrication, and subsequent heat treatment. The uniaxial anisotropic deformation behavior and mechanical properties such as Young’s modulus are obtained by introducing a unidirectional honeycomb structure. The main feature of this structure is that the unmelted powder retained in the pores of the honeycomb structure. After appropriate heat treatment at 1020 °C, necks are formed between the powder particles and between the powder particles and the honeycomb wall, enabling a stress transmission through the necks when the composite is loaded. This means that the powder part has been mechanically functionalized by the neck formation. As a result, a plateau region appears in the stress–strain curve. The stress transfer among the powder particles leads to the cooperative deformation of the composites, contributing to the excellent energy absorption capacity. Therefore, it is expected that the composite can be applied to bone plates on uniaxially oriented microstructures such as long bones owing to its excellent energy absorption capacity and low elasticity to unidirectionally suppress stress shielding.