Total Ankle Replacement (TAR) has become a common surgical procedure for severe Osteoarthritis of the ankle. Unlike hip and knee, current TARs still suffer from high failure rates. A key reason could be their non-anatomical surface geometry design, which may produce unnatural motion and load-transfer characteristics. Current TARs have articular surfaces that are either cylindrical or truncated cone surfaces following the Inman truncated cone concept from more than 60 years ago [1]. Our recent study demonstrated, that the surfaces of the ankle can be approximated by a Saddle-shaped, Skewed, truncated Cone with its apex directed Laterally (SSCL) [2]. This is significantly different than the surface geometry used in current TAR systems. The goal of this study was to develop and test the reliability of an in vitro procedure to investigate the effect of different joint surface morphologies on the kinematics of the ankle and to use it to compare the effect of different joint surface morphologies on the 3D kinematics of the ankle complex. The study was conducted on ten cadaver ankle specimens. Image processing software (Analyze DirectTM) was used to obtain 3D renderings of the articulating bones. The 3D bone models were then introduced into engineering design software packages (, GeomagicTM and InventorTM) to produce a set of four custom-fit virtual articular surfaces for each specimen: 1. Exact replica of the natural surfaces; 2. cylindrical; 3. truncated cone with apex oriented medially according to Inman's postulate; and 4. SSCL. The virtual TAR implants were exported to a 3D printing software and 3D physical models of each implant was produced in PLA using 3D printing (Figure 1). The intact cadaver was tested first in a specially design loading and measuring system [3] in which external moments were applied across the ankle in the three planes of motion and the resulting motion was measured through a surgical navigation system (Figure 1). Each of the four customized implant sets were then surgically introduced one at a time and the test was repeated. From the results, the ankle, subtalar and complex kinematics could be compared to that of the intact natural joint.Background
Methodology
Total ankle replacement (TAR) is the main surgical option in case of severe joint osteoarthritis. The high failure rate of current TAR is often associated to inappropriate prosthetic articulating surfaces designed according to old biomechanical concepts such the fixed axis of rotation, thus resulting in non-physiological joint motion. A recent image-based 3D morphological study of the normal ankle (Siegler et al. 2014) has demonstrated that the ankle joint surfaces can be approximated by a saddle-shaped cone with its apex located laterally (SSCL). We aimed at comparing the kinematic effects of this original solution both with the intact joint and with the traditional prosthetic articulating surfaces via in-silico models and in-vitro measurements. Native 3D morphology of ten normal cadaver ankle specimens was reconstructed via MRI and CT images. Three custom-fit ankle joint models were then developed, according to the most common TAR designs: cylindrical, symmetrically-truncated medial apex cone (as in Inman's pioneering measures), and the novel lateral apex cone, i.e. SSCL. Bone-to-bone motion, surface-to-surface distance maps, and ligament forces and deformations were evaluated via computer simulation. Prototypes of corresponding prosthesis components were designed and manufactured via 3D-printing, both in polymer-like-carbon and in cobalt-chromium-molybdenum powders, for in-vitro tests on the cadaver specimens. A custom testing rig was used for application of external moments to the ankle joint in the three anatomical planes; a motion tracking system with trackers pinned into the bone was used to measure tibial, talar and calcaneal motion (Franci et al. 2009), represented then as tibiotalar, subtalar and ankle complex 3D joint rotations. Each ankle specimen was tested in the intact joint configuration and after replacement of the articulating surfaces according with the three joint models: cylindrical, medial apex cone and SSCL. Results. Small intra-specimen data variability in cycle-to-cycle joint kinematics was found in all cadaver ankles, the maximum standard deviation of all rotation patterns being smaller than 2.0 deg. In-silico ligament strain/stress analysis and in-vitro joint kinematic and load transfer measurements revealed that the novel SSCL surfaces reproduce more natural joint patterns than those with the most common surfaces used in current TAR. TAR based on a saddle-shaped skewed truncated cone with lateral apex is expected to restore more normal joint function. Additional tests are undergoing for further biomechanical validation. The present study has also demonstrated the feasibility and the quality of the full process of custom TAR design and production for any specific subject. This implies a thorough procedure, from medical imaging to the production of artificial surfaces via 3D printing, which is allowing for personalised implants to become the future standard in total joint replacement.
