The Ti–35Nb–7Zr–5Ta (TNZT) alloy is a promising alloy because of its biocompatibility, high specific strength, and low Young's modulus. This work aimed at investigating the viability to process the TNZT alloy by selective laser melting (SLM) and at optimizing the processing parameters to obtain densified bulk samples. The single-track approach was first used, and the optimized laser parameters were determined to produce bulk samples with a relative density of 99.0% when an energy input of 58.3 J/mm3 was used. The effect of porosity on mechanical properties was studied, and the as-built SLM samples presented slightly lower compressive strength than samples produced by Cu-mould suction casting, as a result of a columnar grain structure in the SLMed samples. Prototypes were manufactured, proving the feasibility of manufacturing parts of the TNZT alloy with complex geometry by SLM.
