Introduction

Conventional implant designs in total knee arthroplasty (TKA) are based on metal on UHMWPE bearing couples. Although this procedure is quite successful, early loosening is still a matter of concern. One of the causes for early failure is stress shielding, leading to loss of bone stock, periprosthetic bone fractures and eventually aseptic loosening of the component. The introduction of a polyetheretherketone (PEEK) on UHMWPE bearing couple could address this problem. With mechanical properties more similar to distal (cortical) bone it could allow stresses to be distributed more naturally in the distal femur. A potential adverse effect, however, is that the femoral component and the underlying cement mantle may be at risk of fracturing. Therefore, we analyzed the effect of a PEEK-Optima® femoral component on stress shielding and the integrity of the component and cement mantle, compared to a conventional Cobalt-Chromium (CoCr) alloy implant.

Introduction

Recent reports implicate fretting corrosion at the head-stem taper junction as a potential cause of failure of some large diameter metal-on-metal (MOM) devices. Fretting observed at modular junctions is thought to be a type of ‘mechanically assisted’ corrosion phenomenon, initiated by mechanical factors that lead to an increase in contact stresses and micromotions at the taper interface. These may include: intra-operative taper assembly, taper contamination by debris or body fluids, patient weight and ‘toggling’ of the head or increased frictional torque in a poorly functioning bearing.

We adopted a finite element approach to model the head-taper junction, to analyze the contact mechanics at the taper interface. We investigated the effect of assembly force and angle on contact pressures and micromotions, during loads commonly used to test hip implants.

Summary

Our statistical shape analysis showed that size is the primary geometrical variation factor in the medial meniscus. Shape variations are primarily focused in the posterior horn, suggesting that these variations could influence cartilage contact pressures.

Pegs are often used in cementless total knee replacement (TKR) to improve fixation strength. Studies have demonstrated that interference fit, surface properties, bone mineral density (BMD) and viscoelasticity affect the performance of press-fit designs. These parameters also affect the insertion force and the bone damage occurring during insertion. We aimed to quantify the effect of the aforementioned parameters on the short-term fixation strength of cementless pegs.

6 mm holes were drilled in twenty-four human femora. BMD was measured using calibrated CT-scans, and randomly assigned to samples. Pegs were produced to investigate the effect of interference fit (diameters 6.5 and 7.6 mm), surface treatment (smooth and rough- porous-coating [friction coefficient: 1.4]) and bone relaxation (relaxation time 0 and 30 min) and interactions were studied using a DOE method. Two additional rough surfaced peg designs (diameters 6.2 and 7.3 mm) were included to scrutinize interference. Further, a peg based on the LCS Porocoat® (DePuy Synthes Joint Reconstruction, Leeds, UK) was added as a clinical baseline. In total seven designs were used (n = 10 for all groups). Pegs were inserted and extracted using an MTS machine (Figure 1), while recording force and displacement. Bone damage was defined as the difference between the cross-sectional hole area prior to and after the test.

BMD and interference fit were significant factors for insertion force. BMD had a significant positive correlation with pull-out force and subsequent analyses were therefore normalised for BMD.

Pull-out force increased significantly with interference for both surface coatings at time 0 (p < 0.05). However, after 30 minutes the effect remained significant for rough pegs only (p < 0.05-Figure 2A).

Additionally, the pull-out force increased with diameter in a non-linear manner for the rough pegs (Figure 2B). The two surface treatments were not significantly different to the clinical comparator. Interference fit was the only significant factor for bone damage.

BMD was significant for insertion and pull-out forces, reinforcing the need to account for this factor in biomechanical studies and clinical practice. This study also highlights the importance of time in studying bone interactions, with surface treatment and interference showing different interaction effects with relaxation time. Although smooth pegs initially have a higher pull-out force, this effect reduces over time whereas the pullout force for rough pegs is maintained. Smooth pegs also show time sensitivity in relation to interference and the benefit of increased interference reduces over time, whereas it is maintained in rough pegs. This may be explained by different damage (compressive and abrasive) mechanisms associated with different surface treatments.

In conclusion, BMD and interference fit are significant factors for initial fixation. Bone relaxation plays an important role as it reduces the initial differences between groups. Therefore, these findings should be strongly considered in the design development of cementless TKR.

The effect of an advanced porous surface morphology on the mechanical performance of an uncemented femoral knee prosthesis was investigated. Eighteen implants were inserted and then pushed-off from nine paired femurs (Left legs: advanced surface coating; right legs: Porocoat® surface coating as baseline). Bone mineral density (BMD) and anteroposterior dimension were measured, which both were not significantly different between groups. The insertion force was not significantly different, but push-off force was significantly higher in the advanced surface coating group (P = 0.007). BMD had direct relationship with the insertion force and push-off force (p < 0.001). The effect of surface morphology on implant alignment was very small. We suggest that the surface properties create a higher frictional resistance thereby providing a better inherent stability of implants featuring the advanced surface coating.

Introduction

Recent reports have implicated fretting corrosion at the head-stem taper junction as a potential cause of failure of some large diameter metal-on-metal (MOM) devices. While it has been suggested that larger MOM heads, may induce greater frictional torques at the taper connection, the exact mechanisms underlying fretting corrosion remain poorly understood.

It is likely that the onset of the corrosion process is caused by mechanical factors, such as contact stresses and micromotions occurring at the interface. These stresses and micromotions depend on the fixation of the head onto the stem and may be affected by blood, fat, bone debris or other contaminations. The fixation of the head is achieved intraoperatively through impaction.

To further study this phenomenon, we adopted a finite element approach in which we modeled the head-taper junction fixation mechanics. In this model, we analyzed the effect of impaction force on the micromotions occurring at the head-stem interface.

Introduction

Current clinical practice in total knee arthroplasty (TKA) is largely based on metal on polyethylene bearing couples. A potential adverse effect of the stiff metal femoral component is stress shielding, leading to loss of bone stock, periprosthetic bone fractures and eventually aseptic loosening of the component. The use of a polymer femoral component may address this problem. However, a more flexible material may also have consequences for the fixation of the femoral component. Concerns are raised about its expected potential to introduce local stress peaks on the interface.

The objective of this study was to analyze the effect of using a polyether-etherketone (PEEK-Optima®) femoral component on the cement-implant interface. We analyzed the interface stress distribution occurring during normal gait, and compared this to results of a standard CoCr component.

To achieve desirable outcomes in cementless total knee replacement (TKR), sufficient primary stability is essential. The primary stability inhibits excessive motions at the bone-implant interface, hence providing the necessary condition for osseointegration [1]. Primary stability for cementless TKR is provided by press-fit forces between the bone and implant. The press-fit forces depend on several factors including interference fit, friction between bone and implant surface, and the bone material properties. It is expected that bone mineral density (BMD) will affect the stability of cementless TKR [2]. However, the effect of BMD on the primary stability of cementless femoral knee component has not been investigated in vitro.

Phantom calibrated CT-scans of 9 distal femora were obtained after the surgical cuts were made by an experienced surgeon. Since the press-fit forces of the femoral component mainly occur in the Anteroposterior (AP) direction, the BMD was measured in the anterior and posterior faces for a depth of 5 mm; this depth was based on stress distributions from a Finite Element Analysis of the same implant design. In addition, four strain gauges were connected to different locations on the implant's outer surface and implant strain measured throughout as an indication of underlying bone strain. A cementless Sigma CR femoral component (DePuy Synthes Joint Reconstruction, Leeds, UK) was then implanted using an MTS machine. In order to simulate a ‘normal’ bone condition, the implanted bone was preconditioned for one hour at a cyclic load of 250–1500 N, and a rate of 1 Hz. Finally, the implants were pushed-off from the bone in a high-flex position. Forces and displacements were recorded both during insertion and push-off tests.

Strong correlations were found for insertion and push-off forces with BMD, R² = 0.88 and R² = 0.88, respectively (p < 0.001), so although implantation may be harder in patients with higher BMD, initial stability is also improved. A correlation was also found between final strain and push-off forces (R² = 0.89, p < 0.01) and BMD also showed a strong reverse correlation with total bone relaxation (R² = 0.76, p = 0.023). These results indicate that higher BMD induces higher bone strain, which can lead to improved fixation strength.

There is no consensus on the best fixation method for the TKR but some surgeons prefer a cementless design for young and active patients. The results of our study showed that the primary stability of a cementless femoral knee component is directly correlated with the bone mineral density. Therefore, patient selection based on bone quality may increase the likelihood of good osseointegration and adequate long-term fixation for cementless femoral knee components.

Introduction

Many finite element (FE) studies have been performed in the past to assess the biomechanical performance of TKA and THA components. The boundary conditions have often been simplified to a few peak loads. With the availability of personalized musculoskeletal (MS) models we becomes possible to estimate dynamic muscle and prosthetic forces in a patient specific manner. By combining this knowledge with FE models, truly patient specific failure analyses can be performed.

In this study we applied this combined technique to the femoral part of a cementless THR and calculated the cyclic micro-motions of the stem relative to the bone in order to assess the potential for bone ingrowth.

In cemented total hip arthroplasty, the cement-bone interface can be considerably degraded in less than one year in-vivo service (Figure 1). This makes the interface much weaker relative to the direct post-operative situation. Retrieval studies show that patients do, to a certain extent, not suffer from the degraded cement-bone interface itself. It is, however, unknown whether the degraded cement-bone interface affects other failure mechanisms in the cemented hip reconstruction. A good understanding of the mechanics of the cement-bone interface is therefore essential. The aim of this study was to investigate the mechanics of the cement-bone interface in the direct post-operative and degraded situation by the utilization of finite element analysis (FEA) and laboratory experiments. It was subsequently analyzed how the mechanics of the cement-bone interface affect failure of the cement mantle in terms of crack formation.

In order to investigate the mechanical response of the cement-bone interface, laboratory prepared (direct post-operative state) and postmortem (degraded state) specimens were loaded in various directions in the laboratory and FEA environment. From all specimens, multiple interface morphology parameters were documented, which were related to the interfacial response and subsequently converted to a numerical cohesive model. As a validation, this cohesive model was implemented into two FEA models of transverse sections of cemented hip reconstructions with distinct mechanical characteristics (Figure 2). Finally, the differences in fatigue crack formation in a complete hip reconstruction were determined by varying the cement-bone interface compliance (Figure 3).

When loaded in multiple directions, the interface compliance could not be related to the cement interdigitation depth (r²=0.08). However, compliance did correlate to the gap thickness between the bone and cement (r²=0.81) and the amount of interfacial contact (r²=0.50). Surprisingly, for the same amount of contact, the interface was more compliant in degraded state than in the direct post-operative state. The mechanical response of the experimental and FEA cement-bone interface tests could, independent on the direct post-operative or degraded state, successfully be described by a cohesive model. The cohesive model was even more confirmed by the successful reproduction of the mechanics of the retrieved transverse sections. When the cohesive model was implemented in a complete reconstruction, we found that a compliant cement-bone interface resulted in considerably more fatigue cracks in the cement mantle than a very stiff interface.

This study showed that an increased compliancy of the cement-bone interface results in an increase of cement cracks in the cement mantle. It is therefore crucial to minimize the interfacial gaps and, as a result, increase the amount of contact between the bone and cement to generate a stiff cement-bone interface. It is, unfortunately, unknown how this well fixed interface can be maintained. We finally conclude that the derived cohesive model of the cement-bone interface can be used for multiple applications in orthopaedics, including pre-clinical of implants and patient specific studies of failed cemented reconstructions.

Introduction

Hip resurfacing arthroplasty has gained popularity as an alternative for total hip arthroplasty. Usually, cemented fixation is used for the femoral component. However, each type of resurfacing design has its own recommended cementing technique.

In a recent investigation the effect of various cementing techniques on cement mantle properties was studied. This study showed distinct differences in cement mantle volume, filling index and morphology.

In this study, we investigated the effect of these cement mantle variations on the heat generation during polymerization, and its consequences in terms of thermal bone necrosis.

The stability of cemented hip implants relies on the fixation of the cement mantle within the bone cavity. This fixation has been investigated in experiments with cement-bone interface specimens, which have shown that the cement-bone interface is much more compliant than is commonly assumed. Other studies demonstrated that the mechanical response of the interface is dependent on penetration of the cement into the bone. It is, however, unclear how cement penetration exactly affects the stiffness and strength of the cement-bone interface. We therefore used finite element (FE) models of cement-bone specimens to study the effect of cement penetration depth on the micromechanical behavior of the interface.

The FE models were created based on micro computed tomography (micro CT) data of two small cement-bone interface specimens (8x8x4 mm). The specimens had distinct differences with respect to interface morphology. In these models we varied the penetration depth, with six different penetration levels for each model. We then incrementally deformed each model in tension and in shear, until failure of the models. Failure was simulated to occur in the bone and cement when the local ultimate tensile stress was exceeded, by locally reducing the material stiffness to near zero. From the resulting force-displacement curves we established the apparent tensile stiffness and strength for each of the models.

Our results indicated that the strength and stiffness of the cement-bone interface increased with increasing cement penetration depth, both in tension and in shear. However, after reaching a certain penetration depth, both strength and stiffness did not further increase. This depth was dependent on the specific interface morphology. We furthermore found that the strength of the models was higher in shear than in tension. After failure of the models, damage was mainly found in the cement, rather than in the bone.

The FE-based techniques developed for the current study are suitable for exploration of a variety of aspects that may affect the cement-bone interface micromechanics, such as biological changes to the bone and variations of cement material properties.

Introduction: Finite element (FE) simulation of damage accumulation in the femoral cement mantle is widely used to predict failure of hip prostheses. It is often assumed that the stem-cement interface remains bonded, although debonding is thought to affect cement stress and damage. Rough stems may reduce subsidence, but have been reported to have a detrimental effect on implant survival. Other factors thought to influence cement damage include stem design and orientation and cement thickness. This study investigates the effect of cement mantle thickness and stem malpositioning on cement damage around a smooth, collared implant, and the extent to which this is affected by debonding of the stem-cement interface.

Method: Three FE meshes were built to represent proximal femora with Stanmore Hip prostheses implanted into a thick (2.5 mm) and a thin (1.0 mm) cement mantle, and another thin (1.0 mm) mantle with the implant tilted in varus to achieve a minimal thickness of 0.1 mm laterally. Each model consisted of 4304 eight-noded brick elements with frictional contact at the stem-cement interface. Two analyses were run for each model, in which the stem-cement interface was (a) fully bonded, and (b) fully debonded, with Coulomb frictional contact using a friction coefficient of 0.5. Standardised femur geometry and elastic properties were used. Creep and non-linear damage accumulation in the cement mantle under cyclic loading was modelled using subroutines developed by Stolk et al. (2003). Boundary conditions were applied representing a peak stair-climbing load.

Results: Bonded cases showed extensive cracking around the tip in all cases. Debonded cases had 4–8 times less cracking, which was much more focused at the tip; only the poorly-centralised mantle showed extensive damage elsewhere, in the very thin lateral region. When bonded, the thick mantle had least cracks and the poorly-centralised mantle had most; in the debonded cases, there was no major difference between thick, thin, and poorly-centralised mantles. For each cement mantle geometry, peak maximum principal cement stress was consistently lower in the debonded case than in the bonded case.

Discussion: Our results show greater, more widely distributed cracking in bonded than debonded cement mantles, in contrast with previous studies involving collarless implants. For a collared stem, calcar contact prevents subsidence, allowing cement stress relaxation. A possible explanation for our result is that debonding enhances the stress relaxation process, reducing and redistributing interfacial and shear stresses; thus reducing damage rates. In contrast, a debonded collarless stem subsides continuously, sustaining high cement stress levels and damage rates. These results may explain the disappointing clinical performance of some rough-surfaced prostheses. Our results suggest that bonding might increase both cement damage and its sensitivity to cement thickness. Similar results for all debonded cement mantles indicate that cement thickness may be less critical than previously thought for smooth, collared prostheses. Bonding should not be assumed in FE studies of smooth stems which clinically are likely to debond; cement damage simulation should be extended to incorporate the debonding process.

Introduction: It is generally accepted that the cement mantle surrounding femoral hip implants should be at least 2–3 mm thick. To achieve that goal, manufactures or surgeons often undersize the stem compared to the broach. However, some implants, such as the Charnley-Kerboul stem, are typically cemented line-to-line i.e. with a broach and stem of the same size. Despite their “minimal” cement mantle, these stems are very successful. This apparent contradiction is known as the “French Paradox”[1]. We used a finite element analysis (FEA) model to investigate the effect of these different cementation philosophies on cement crack propagation and rotational stem stability.

Material and Methods: Based on a CT-scan image of a Charnley-Kerboul plastic stem replica[2], twelve FEA models were created. By decreasing the stem size (4 stems), the average cement mantle thickness increased (1.71–3.77mm). However, the incidence of cement mantle defects (< 1mm) and areas of thin cement (< 2mm) decreased (defects: 34.7–0.0%; thin cement: 40.7–0.0%). The amount of cortical bone support was varied (3 times) between 18.4 and 72.2%. All models were alternately loaded with a cyclic torque load (25.8Nm) and a transversal load (400N) in a ratio of 9:1 for two million cycles. The model predicted fatigue crack formation within the cement and rotational stem stability.

Results: Overall, increasing implant size and increasing the amount of cortical bone support to the cement, improved resistance to accumulated cement damage and rotational stem stability. In both models with undersized stems, more cement cracks and full thickness (FT) cement fractures appeared after less loading cycles than in both models with canal-filling stems. Worst results were obtained with a severely undersized implant surrounded by a thick cement mantle that was poorly supported by cortical bone (first FT crack after < 100 000 cycles, > 220 initiated cracks and 0.6° of implant rotation after 2 million cycles). Best results were obtained with the maximal canal-filling stem surrounded by a thin and deficient cement mantle that was well supported by cortical bone (no FT cracks, < 10 initiated cracks and 0.3° of implant rotation after 2 million cycles).

Conclusion: This study emphasizes the importance of an adequate cementation technique that aims at pressurizing cement up to the cortical bone. This protects the cement mantle against fatigue fracture and stabilises the implant especially if the stem is undersized. From a mechanical point of view, canal-filling stems make sense. They limited the formation of cement cracks and improved rotational stability to the implant. This could explain the excellent results obtained by implants that are cemented line-to-line.