ABSTRACT The interference screw is a widely used fixation device in the anterior cruciate ligament (ACL) reconstruction surgeries. Despite the generally satisfactory results, problems of using interference screws were reported. By using additive manufacturing (AM) technology, we developed an innovative titanium alloy (Ti6Al4V) interference screw with rough surface and inter‐connected porous structure designs to improve the bone‐tendon fixation. An innovative Ti6Al4V interference screws were manufactured by AM technology. In vitro mechanical tests were performed to validate its mechanical properties. Twenty‐seven New Zealand white rabbits were randomly divided into control and AM screw groups for biomechanical analyses and histological analysis at 4, 8, and 12 weeks postoperatively; while micro‐CT analysis was performed at 12 weeks postoperatively. The biomechanical tests showed that the ultimate failure load in the AM interference screw group was significantly higher than that in the control group at all tested periods. These results were also compatible with the findings of micro‐CT and histological analyses. In micro‐CT analysis, the bone‐screw gap was larger in the control group; while for the additive manufactured screw, the screw and bone growth was in close contact. In histological study, the bone‐screw gaps were wider in the control group and were almost invisible in the AM screw group. The innovative AM interference screws with surface roughness and inter‐connected porous architectures demonstrated better bone‐tendon‐implant integration, and resulted in stronger biomechanical characteristics when compared to traditional screws. These advantages can be transferred to future interference screw designs to improve their clinical performance. The AM interference screw could improve graft fixation and eventually result in better biomechanical performance of the bone‐tendon‐screw construct. The innovative AM interference screws can be transferred to future interference screw designs to improve the performance of implants. © 2018 Orthopaedic Research Society. Published by Wiley Periodicals, Inc. J Orthop Res 36:2633–2640, 2018. By using additive manufacturing (AM) technology, we developed an innovative titanium alloy (Ti6Al4V) interference screw with rough surface and inter‐connected porous structure designs to improve thebone–tendon fixation in the anterior cruciate ligament (ACL) reconstruction surgeries. Our results showed that the AM interference screw could improve graft fixation and eventually result in better biomechanical performance of the bone‐tendon‐screw construct. The innovative AM interference screws can be transferred to future interference screw designs to improve the performance of implants.