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In this study, a novel (α+β) dual-phase Ti–19Nb–0.6O was developed and processed via additive manufacturing, featuring ultra-low Young’s modulus of 42 GPa approximating that of human bone, coupled with high strength (919 MPa), and 15% elongation. By utilizing post-heat treatment to adjust the distribution and content of the precipitated α phase, the elemental distribution of Nb and O between α and β phase was effectively manipulated, meanwhile, the β matrix stability was regulated, enabling the attainment of lower modulus and higher strength. These findings advance the development of biomedical titanium alloys produced using additive manufacturing, characterized by excellent mechanical performance.

Abstract Titanium (Ti) dental scaffolds are widely used in dental prosthetics due to their excellent mechanical properties and biocompatibility. However, conventional Ti scaffolds manufactured through machining often do not fit perfectly with the bone defect site. Laser powder bed fusion (LPBF) technology enables the personalised manufacturing of custom‐made Ti scaffolds. A custom‐made Ti scaffold was prepared using LPBF and its surface roughness was improved through chemical polishing. To enhance the surface roughness, a nitric acid mixed solution with a specific composition of HF: HNO3:C3H6O3 = 2:2:3 was used. The polishing mechanism was investigated by adjusting the F/Ti ratio to control the formation and dissolution of the oxide film. As a result, the surface of the Ti scaffold after polishing exhibited a smooth and flat appearance compared to the LPBF part, with a reduced surface roughness (Ra) of 1.23 ± 0.19 μm. The custom‐made Ti scaffold also demonstrated favourable mechanical properties, with a bending strength of 335.18 ± 33.62 MPa and stiffness of 2.13 ± 0.21 GPa. Furthermore, in vitro cell tests confirmed the excellent biocompatibility of the custom‐made Ti scaffold. The authors present a feasible strategy for the further clinical application of custom‐made Ti scaffolds, offering enhanced surface properties and addressing the limitations of conventional machining methods.