Effect of Sample Thickness and Post-Processing on Mechanical Properties of 3D-Printed Titanium Alloy

3D printing of beta titanium alloys for biomedical applications is currently in great demand, both for material reasons and for the possibility of producing very complex replacements, often directly tailored to the patient. Gyroidal and similar structures are ideal for biomedical replacements but their manufacturing require specific additive technology and post-processing like annealing or etching. The aim of this work is to determine the mechanical properties of Ti25Nb4Ta8Sn alloy which overcomes Ti6Al4V in biomedical applications. The results showed that Ti6Al4V exhibited a significantly higher ultimate tensile strength (up to 1200 MPa) compared with the beta titanium alloy Ti25Nb4Ta8Sn (up to 360 MPa), while the latter demonstrated a substantially lower elastic modulus (∼ 40–50 GPa), beneficial for biomedical applications. Annealing improved strength and reduced internal stresses in both alloys, while etching effectively removed residual powder but slightly decreased mechanical integrity. These findings provide a quantitative basis for optimizing printing and post-processing parameters of beta titanium alloys for implant design. The properties will be used for future numerical simulations of implants made from Ti25Nb4Ta8Sn alloy based on discrete particle grid models.