Biocompatible metastable β-titanium alloys are promising for biomedical implants due to their excellent mechanical compatibility with bone. However, their production via laser powder bed fusion (LPBF) remains challenging due to a poor diversity of powder. This study optimizes the in situ alloying from commercially pure elemental powders to elaborate a Ti-22Zr-11Nb-2Sn (at%) alloy composition achieving dense parts with few unmolten particles and mechanical properties comparable to those of Ti-6Al-4V. To further enhance mechanical performance, a thermal treatment at 850°C for 30 minutes followed by water quenching was applied after manufacturing. The quenched Ti-22Zr-11Nb-2Sn alloy exhibits excellent mechanical properties, highlighting the influence of heat treatment on microstructure and mechanical performance. These findings demonstrate the potential of in situ alloying combined with thermal treatments to tailor the properties of β-titanium alloys for advanced biomedical applications, such as hip prosthesis or dental implants.

Keywords: Additive manufacturing, In situ alloying, Titanium alloys, Microstructure, Mechanical properties.