Powder-based 3D printing of titanium often leads to increased porosity of final products and therefore, increased risk of breakage. To investigate this problem, researchers from Carnegie Mellon University and the Argonne National Laboratory inspected Ti-6Al-4V titanium and learned that as the titanium powder heats, gases trapped in the material can create pores. This issue has been established and yet to be fixed.

Professor Kenji Shimada and his research team from Carnegie Mellon University’s College of Engineering have developed "Medical Phantom Model" ”, which uses 3D printing to create a realistic looking and feeling hands-on training model for surgeons and by using a clear ballistic gel, a 10% synthetic non-fouling gel material typically used for testing ammunition and to simulate bullet wounds. Currently it is being used for Clubfoot, or Congenital Talipes Equinovarus (CTEV), a congenital deformity which is distinguished by one or both feet being turned inwards and upwards and results in serious mobility problems if left untreated.