Porous surfaces on orthopaedic implants have been shown to promote tissue ingrowth. This study evaluated biological fixation of novel additively manufactured porous implants with and without hydroxyapatite coatings in a canine transcortical model.

Laser rapid manufacturing (LRM) Ti6Al4V cylindrical implants were built with a random interconnected architecture mimicking cancellous bone (5.2 mm diameter, 10mm length, 50–60% porous, mean pore size 450μm). Three groups were investigated in this study: as-built with no coating (LRM), as-built coated with solution precipitated hydroxyapatite (LRM-PA), and as-built coated with a plasma sprayed hydroxyapatite (LRM-PSHA). Implants were press-fit into a 5mm unicortical, perpendicular drill hole in the femoral diaphysis of the left and right femurs in 12 canines. Right femora were harvested for histology (SEM, bone ingrowth into implant within cortical region) and left femora for mechanical push-out testing (shear strength of bone-implant interface) at 4 and 12 weeks (N=6, un-paired Student's t-test, p=0.05).

For mean bone ingrowth, there was no significant difference between groups at 4 weeks (LRM, LRM-PA, LRM-PSHA: 41.5+8.6%, 51+5.5% and 53.2+11%, respectively) or 12 weeks (LRM, LRM-PA, LRM-PSHA: 64.4+2.8%, 59.9+7.6%, 64.9+6.4%, respectively). LRM and LRM-PA implants had more bone ingrowth at 12 weeks than 4 weeks (p < 0 .05). Mean shear strength of all implants at 12 weeks (LRM, LRM-PA, LRM-PSHA: 39.9+3.6MPa, 33.7+4.6MPa, 36+4.1MPa respectively) were greater than at 4 weeks (LRM, LRM-PA, LRM-PSHA: 21.6+2.8MPa, 20.7+1.1MPa, 20.2+2.5MPa respectively) (p < 0 .05). No significant difference was observed between all groups at 4 or 12 weeks.

Overall, this canine study confirmed the suitability of this novel additive manufacturing porous material for biological fixation by bone ingrowth. All implants exhibited high bone ingrowth and mechanical shear strength in this canine model. No difference was observed between uncoated and hydroxyapatite coated implants.

Introduction

In hip arthroplasty, it has been shown that assembly of the femoral head onto the stem remains a non-standardized practice and differs between surgeons [1]. Pennock et al. determined by altering mechanical conditions during seating there was a direct effect on the taper strength [2]. Furthermore, Mali et al. demonstrated that components assembled with a lower assembly load had increased fretting currents and micromotion at the taper junction during cyclic testing [3]. This suggests overall performance may be affected by head assembly method. The purpose of this test was to perform controlled bench top studies to determine the influence of impaction force and compliance of support structure (or damping) on the initial stability of the taper junction.

Statement of Purpose

Mechanically assisted crevice corrosion of modular tapers continues to be a concern in total joint replacements as studies have reported increases in local tissue reactions¹. Two surgical factors that may effect taper seating mechanics are seating load magnitude and orientation.

In this study 12/14 modular taper junctions were seated over a range of loads and loading orientations. The goals of this study were to assess the effects of load magnitude and orientation on seating load-displacement mechanics and to correlate these to the pull-off load.