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A bimodal globularized microstructure in contrast to martensitic laths is known to impart high strength and toughness in Ti-6Al-4V. Heat treatment for the phase transformation of the laths to the globularized microstructure must be preceded by plastic deformation. This work reports an innovative strategy to obtain the bimodal microstructure consisting of globular α in additively manufactured Ti-6Al-4V alloy by heat treatment alone. The heat treatment schedule involves repeated thermal cycling close to but below the β transus temperature to form globular α eliminating the need for plastic deformation prior to heat treatment. A new mechanism of globularization other than known in literature is proposed to explain the formation of globular α. The inherent dislocation sub-structure of the martensitic laths initiates globularization by thermal grooving and boundary splitting but is unable to completely globularize the …