Research on additive manufacturing of Ti-6Al-4V material based on digital light processing technology

Titanium alloy components with microscale structural features are critically important for applications in aerospace, consumer electronics, and biomedical implants. This study presents a novel approach for fabricating Ti-6Al-4V components with micron-scale pores and complex curved porous structures using digital light processing (DLP) technology. We developed a photocurable Ti-6Al-4V slurry suitable for DLP technology, and successfully prepared and sintered Ti-6Al-4V samples with micron-scale pores and complex curved porous structures. A systematic analysis of the phase composition, microstructure, and mechanical properties of the sintered samples was conducted. The results revealed that residual carbon from the pyrolysis of polymers during the debinding process reacted in situ with titanium during sintering to form TiC particles. These particles, acting as reinforcement phases, were uniformly distributed within the matrix, thereby improving the mechanical properties of the Ti-6Al-4V samples. This work demonstrates its feasibility in manufacturing titanium alloys with micro-scale structures providing a novel method and process reference for Ti-6Al-4V materials.