Mg-based scaffolds are emerging as architected, load-bearing constructs that couple temporary mechanical support with bioactive, self-resorbing behavior. This review integrates advances in geometric design, fabrication, and biological translation of Mg-based scaffolds. The study comprehensively discusses key design parameters, including porosity, pore size, pore shape, pore orientation, strut thickness, alloy composition, and hybrid surface modification strategies. It further highlights that triply periodic minimal surfaces and optimized lattices with tailored interconnected porosity achieve cancellous-bone-like mechanics while enhancing permeability, osteogenesis, angiogenesis, and pro-healing immunomodulation. Various fabrication routes including powder metallurgy, replica casting, laser powder-bed fusion and binder-jetting techniques are compared with respect to microstructural control, defect tolerance, corrosion-fatigue, and scalability. Surface modifications, including fluoride/Ca–P conversion layers, layered double hydroxides, and polymer-ceramic hybrid coatings, act as physical barrier and ion-regulating interfaces that slow the initial corrosion burst, buffer local alkalinity, and provide controlled Mg²⁺ release within a therapeutic window. Collectively, in-vitro and in-vivo investigations show that architected Mg scaffolds are biocompatible, generate only transient hydrogen, and degrade in vivo more slowly and uniformly than static immersion predicts. Bone ingrowth tracks the resorption front, enabling progressive load transfer from the scaffold to regenerating tissue. Compared with planar Mg devices, these lattices mitigate stress shielding, conform to irregular defects, and provide orders-of-magnitude greater surface for osseointegration. To address key translational challenges, including synchronizing scaffold degradation with bone healing, ensuring corrosion-fatigue reliability under physiological conditions, and meeting regulator-compliant manufacturing standards, the review highlights the role of Mg-based biocomposite scaffolds with hybrid surface treatments. These surface strategies improve structural persistence and biological compatibility. Together, they strengthen the pathway toward full-scale clinical translation of Mg scaffolds for orthopedic applications.

In recent years, the exploration of magnesium (Mg) alloys has gained momentum in the pursuit of developing biodegradable implants. However, its rapid degradation in physiological environments poses significant challenges, leading to premature mechanical failure and tissue damage. While several chemical coating techniques have been attempted, in-situ mineralization of Ca-P rich apatite has shown potential to overcome the limitations of ex-situ coatings. This study investigated the influence of surface topography resulting from different wire electric discharge settings, Low Discharge Rate (LDR) and High Discharge Rate (HDR), towards in-situ apatite mineralization and anchoring on Mg alloys during in-vitro and in-vivo conditions. The observed apatite mineralization on the LDR-Mg sample demonstrated a dense microflower-shaped structure, closely resembling the ideal Hydroxyapatite (HA) configuration with a Ca/P ratio of 1.60. Notably, the apatite mineralization on the LDR-Mg sample significantly suppressed the corrosion current density (I_corr). This resulted in a 1.6 mm/year corrosion rate with corrosion inhibition efficiency (η_c) of 78 % after 7 days of immersion in SBF. During in vitro degradation, the LDR-Mg sample maintained the lowest hydrogen evolution rate, relative weight changes, and pH variations compared to Mg and HDR-Mg samples. After skin implantation up to 10 weeks, the LDR-Mg samples indicated enhanced implant-tissue integration followed by a marginal volume loss of 11 %. The H&E staining analysis and serum indices reveal that LDR-Mg samples exhibit the highest biocompatibility, with well-preserved tissue architecture and minimal organ damage. The findings highlight the potential of spark tuning on Mg alloys for stable in-situ apatite mineralization, enhancing anticorrosion performance and bioactivity for full-scale clinical applications.