Powder bed fusion (PBF) has emerged as a useful metal-three-dimensional (3D) printing technology for manufacturing porous structures; it has been widely employed for the production of medical implants. Multiple previous reports have suggested that the bone ingrowth characteristics of porous structures, among the most important factors for medical implants, are affected by 3D printing parameters (e.g., pore shape). The topography of 3D-printed metal surfaces can also influence cellular responses, including osteoblast differentiation. The surface topography may change according to the shape of the printed pores. Nevertheless, it remains unclear how the surface topography changes. In addition, it is still unknown how the pore shape and the resulting surface topography can further impact the bone ingrowth efficiency of the porous structure. Therefore, to better understand the relationship, we prepared Ti–6Al–4V specimens with different pore shapes (i.e., circular, triangular, and rectangular) using the PBF method, then analyzed the surface topographies of these 3D scaffolds based on curvature and roughness profiles. Through subsequent in vitro studies, we investigated how changes in pore shape and surface topography affect the activity of Saos-2 human osteosarcoma cells. The results of this study confirmed that the curvature radii and local surface roughness change according to pore shape because of the characteristics of PBF. Furthermore, differences in local surface topography and pore shape led to differences in cell proliferation and differentiation. Through our findings, we anticipate that the meticulous design of pore shape and sophisticated control of the processing parameters, such as laser speed and paths, in the fabrication of orthopedic and dental implants will result in significantly enhanced bone ingrowth efficiency.
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