Zeng, GuangZahiri, Saden H.Gulizia, StefanChen, YapingChen, Xiao BoCole, Ivan2026-07-032026-07-030884-2914ORCID:/0000-0001-6582-1457/work/219176285https://hdl.handle.net/1885/733812502Rapid advances in 3D hybrid additive manufacturing have provided opportunities to the use of Ta as a highly effective biomaterial. In this study, we used electron beam melting (EBM) process to fabricate Ti–6Al–4V 3D structures (EBM-Ti64) and then applied cold spray additive manufacturing to deposit commercially pure (CP) Ti, Ti–Ta composite and pure Ta coatings on the EBM-Ti64 substrate to explore the biocompatibility of Ti–Ta composite structures through hybrid additive manufacturing. The microstructure, microhardness, corrosion resistance and biocompatibility were evaluated. Feedstock powders and process parameters of cold spray determine the microstructures of the deposited coating. Microhardness and indentation testing of Ti–Ta composite reveal the weight ratio of Ta influences the microhardness. In particular, higher corrosion resistance was achieved on cold sprayed Ti–30%Ta composite compared to CP Ti and pure Ta coatings. Moreover, live/dead and MTS assay demonstrate that the cold sprayed coatings were non-toxic, while the EBM-Ti64 substrate shows some cytotoxicity signs which might be related to the released toxic ions. This study confirms the biocompatible Ti–Ta composite structures can be manufactured through a combination of EBM and cold spray, opening opportunities for the rapid hybrid manufacture of biocompatible implants. Graphic abstract: [Figure not available: see fulltext.].The authors would like to thank the facilities, scientific and technical assistance of the Australian Microscopy & Microanalysis Research Facilities (AMMRF), MicroNano Research Facility (MNRF) at RMIT University and the Cold Spray Laboratory at CSIRO. The authors also acknowledge the scientific assistance of Dr Zeyad Nasa, Dr Adam Truskewycz and Mr Qiushi Deng from RMIT University and Dr Alejandro Vargas Uscategui, Mr David Ritchie, Dr Darren Fraser, Mr Andrew Urban, Dr Lathabai Sri, Mrs Jessica Andrade, Dr Veronica Glattauer, Dr Malisja de Vries and Mr Mark Greaves from CSIRO. G.Z. acknowledges the support through “Australian Government Research Training Program Scholarship” and RMIT Research Stipend Scholarship. This work was performed partially at the Melbourne Centre for Nanofabrication (MCN) at Victorian Node of the Australian National Fabrication Facility (ANFF). The authors would like to thank the facilities, scientific and technical assistance of the Australian Microscopy & Microanalysis Research Facilities (AMMRF), MicroNano Research Facility (MNRF) at RMIT University and the Cold Spray Laboratory at CSIRO. The authors also acknowledge the scientific assistance of Dr Zeyad Nasa, Dr Adam Truskewycz and Mr Qiushi Deng from RMIT University and Dr Alejandro Vargas Uscategui, Mr David Ritchie, Dr Darren Fraser, Mr Andrew Urban, Dr Lathabai Sri, Mrs Jessica Andrade, Dr Veronica Glattauer, Dr Malisja de Vries and Mr Mark Greaves from CSIRO. G.Z. acknowledges the support through “Australian Government Research Training Program Scholarship” and RMIT Research Stipend Scholarship. This work was performed partially at the Melbourne Centre for Nanofabrication (MCN) at Victorian Node of the Australian National Fabrication Facility (ANFF).12enPublisher Copyright: © 2021, The Author(s), under exclusive licence to The Materials Research Society.Cold sprayEBMHybrid additive manufacturingTi–Ta composite structures2021-09-2810.1557/s43578-021-00190-w85104555566