Surface topography control in CoCrMo alloy additive manufacturing through laser powder bed fusion process

Laser powder bed fusion (LPBF) enables precise fabrication of CoCrMo alloy components for biomedical applications; however, achieving optimal surface properties for orthopedic implants remains challenging. Surface engineering plays a pivotal role in enhancing both biological and tribological responses, particularly in improving the adhesion of bioactive coatings. This study integrates LPBFed surface optimization with atmospheric plasma-sprayed (APS) hydroxyapatite (HAp) coatings to enhance interfacial bonding strength. LPBF process parameters were systematically optimized to tailor surface roughness, followed by APS deposition of HAp coatings on the optimized CoCrMo substrates. In this study, LPBF process parameters were varied to fabricate CoCrMo samples, and specimens were evaluated based on microhardness (320–375 ± 12 HV 0.5 ), porosity (