An ultra-high molecular weight polyethylene (UHMWPE) is widely used as bearing material in artificial joints, however, UHMWPE wear particles are considered to be a major factor in long-term osteolysis and loosening of implants. The wear particles activate macrophages, which release cytokines, stimulating osteoclasts, which results in bone resorption. The biological activity of the wear debris is dependent on the volume and size of the particles produced. Many researchers reported that the volume and size of particles were critical factors in macrophage activation, which particles in the size range of 0.1–1 mm being the most biological active.

To minimize the amount of wear of UHMWPE and to enlarge the size of UHMWPE wear particle, a nano-level surface textured on Co-Cr-Mo alloy as a counterface material was invented (Figure 1). Although the generally-used surface for a conventional artificial joint has 10 nm roughness (G-1), the nano-level surface has a superfine surface of 1 nm with groove and dimples against the bearing area. The existence probability of groove or dimples, and their surface waviness were adjusted (P-1, 2, 3, 4 and W-1, 2).

Pin-on-disc wear tester capable of multidirectional motions was used to verify that the nano-textured surface is the most appropriate for artificial joint. UHMWPE pin with an average molecular weight of 6.0 million was placed in contact with the disc and the contact pressure was 6.0 MPa. The disc and pin were lubricated by a water-based liquid containing the principal constituents of natural synovial fluid. Sliding speed of 12.12 mm/s had been applied for total sliding distance of 15 km.

The nano-textured surfaces reduced the amount of UHMWPE wear, this would ensure the long-term durability of artificial joint (Figure 2). The wear particles isolated from lubricating liquid were divided broadly into two categories; one is “simple type” and the other is “complicated type”. The lengths in a longitudinal direction (L_l) and its orthogonal direction (L_s) for each particles (>150) were measured, and the each aspect ratio (= L_l/L_s) was calculated. No significant difference was found in the ratio between simple type and complicated type, and in the distributions of aspect ratios. However, the distributions of L_l, which means the size of UHMWPE wear particle, were dramatically changed by using the nano-textured surface (Figure 3). These results suggest that the nano-textured surface does not change the morphological aspect of UHMWPE particle but enlarges the size of UHMWPE particle.

Cells (RAW264.7, blood, Mouse) were cultured with the particles in supplemented Dulbecco's modified Eagle's medium for 24 h in an atmosphere of 5% CO₂ in air at 37 degrees C, and the quantitative PCR was performed for genetic expression of IL-6. The wear debris generated on the nano-textured surface inhibited the genetic expression of IL-6, which does not induce the tissue reaction and joint loosening.

An artificial articular cartilage is being investigated for use in joint replacement. The low elastic modulus lining on the bearing surface is used to promote a continuous lubricant film between the articulating surfaces and hence reduce both friction and wear.

Polyvinyl formal (PVF) as an artificial articular cartilage was proposed to prolong the service life of joint replacement. The major raw material of the PVF was a polyvinyl alcohol (PVA) hydrogel, which was one of the few polymers with hydrophilic properties. It is anticipated to realize a wide range of clinical applications due to its high water-holding capacity and high biocompatibility. However, a major problem with PVA hydrogel is its low wear resistance. The PVF was made by performing a chemical cross-linking reaction in PVA, and its pore diameter, porosity, and beam density could be controlled by varying the concentrations of cross-linking agent (formaldehyde) and catalyst (sulfuric acid).

The knee joint simulator was used for investigating the wear performance of the PVF. The load and motion cycles were taken from ISO 14243-3. The peak load was 2.6 kN, and the walking cycle was 1.0 seconds. The lower PVF specimen represented the flat tibial component of the joint, and the femoral component was artificial knee joint which made from Co-Cr-Mo alloy. The lubricant was a waterbased liquid containing the principal constituents of synovial fluid.

The PVF survived for more than 1.0 million cycles. Enlargement of the PVF creep deformation by prolongation of simulating time was not obvious. Although the tribological property in fatigue wear produced by ploughing friction was inadequate, it was obvious that the PVF was a potential material for developing a load bearing system with hydration lubrication.