Aims. The purpose of this study was to evaluate the biological fixation of a 3D printed porous implant, with and without different hydroxyapatite (HA) coatings, in a canine model. Materials and Methods. A canine transcortical model was used to evaluate the characteristics of bone ingrowth of Ti6Al4V cylindrical implants fabricated using laser rapid manufacturing (LRM). At four and 12 weeks post-implantation, we performed histological analysis and mechanical push-out testing on three groups of implants: a HA-free control (LRM), LRM with precipitated HA (LRM-PA), and LRM with plasma-sprayed HA (LRM-PSHA). Results. Substantial bone ingrowth was observed in all LRM implants, with and without HA, at both time periods. Bone ingrowth increased from 42% to 52% at four weeks, to 60% to 65% at 12 weeks. Mechanical tests indicated a minimum shear fixation strength of 20 MPa to 24 MPa at four weeks, and 34 MPa to 40 MPa at 12 weeks. There was no significant difference in the amount of bone ingrowth or in the shear strength between the three implant types at either time period. Conclusion. At four and 12 weeks, the 3D printed porous implants exhibited consistent bone ingrowth and high mechanical shear strength. Based on the results of this study, we confirmed the suitability of this novel new additive manufacturing porous material for biological fixation by bone ingrowth. Cite this article: Bone Joint J 2019;101-B(6 Supple B):62–67

Aims

The main advantage of 3D-printed, off-the-shelf acetabular implants is the potential to promote enhanced bony fixation due to their controllable porous structure. In this study we investigated the extent of osseointegration in retrieved 3D-printed acetabular implants.

3D printing acetabular cups offers the theoretical advantage of enhanced bony fixation due to greater design control of the porous implant surfaces. Analysing retrieved 3D printed implants can help determine whether this design intent has been achieved. We sectioned 14 off-the-shelf retrieved acetabular cups for histological analysis; 7 cups had been 3D printed and 7 had been conventionally manufactured. Some of the most commonly used contemporary designs were represented in both groups, which were removed due to either aseptic loosening, unexplained pain, infection or dislocation. Clinical data was collected for all implants, including their age, gender, and time to revision. Bone ingrowth was evaluated using microscopic assessment and two primary outcome measures: 1) bone area fraction and 2) extent of bone ingrowth. The additively manufactured cups were revised after a median (IQR) time of 24.9 months (20.5 to 45.6) from patients with a median (IQR) age of 61.1 years (48.4 to 71.9), while the conventional cups had a median (IQR) time to revision of 46.3 months (34.7 to 49.1, p = 0.366) and had been retrieved from patients with a median age of 66.0 years (56.9 to 68.9, p = 0.999). The additively and conventionally manufactured implants had a median (IQR) bone area fraction of 65.7% (36.4 to 90.6) and 33.9% (21.9 to 50.0), respectively (p < 0.001). A significantly greater amount of bone ingrowth was measured into the backside of the additively manufactured acetabular cups, compared to their conventional counterparts (p < 0.001). Bone occupied a median of 60.0% and 5.7% of the porous depth in the additively manufactured and conventional cups, respectively. 3D printed components were found to achieve a greater amount of bone ingrowth than their conventionally manufactured counterparts, suggesting that the complex porous structures generated through this manufacturing technique may encourage greater osteointegration

Introduction. Porous surfaces developed over the past decades have been shown to promote tissue ingrowth. Hydroxyapatite (HA) coatings have been added to these porous coatings in an attempt to further augment bone ingrowth. The development of additive manufacturing techniques has allowed for precision in building these complex porous structures. The effect of supplemental HA coatings on these new surfaces is unclear. The purpose of this study is to evaluate the biological fixation of a novel 3D printed porous implant in a canine model. In addition, we evaluated the effect of different HA coatings on this 3D printed implant. Methods. A canine transcortical model was used to evaluate the performance of three different laser rapid manufacturing (LRM) Ti6Al4V cylindrical implants (5.2 mm diameter, 10mm length): LRM with precipitated hydroxyapatite (P-HA), LRM with plasma sprayed hydroxyapatite (PS-HA), and a hydroxyapatite-free control (No-HA). The implants were 50–60% porous with a mean pore size of 450 μm and have a random interconnected architecture with irregular pore sizes and shapes that are designed based on the structure of cancellous bone. A lateral approach to the femoral diaphysis was used to prepare 5 mm unicortical, perpendicular drill holes in 12 canines. One of each implant type was press-fit into each femur. The femora were harvested at both 4 and 12 weeks post implantation, radiographed and prepared for either mechanical push-out testing to assess the shear strength of the bone-implant interface (left femora, N=6) or for histological processing (right femora, N=6). An un-paired Student's t-test was used to compare statistical significance between the 4 and 12-week results, as well as differences due to implant type; p<0.05 was considered significant. Results. The post-mortem contact radiographs demonstrated substantial condensation of bone around the implants at both 4 and 12 weeks. Bone ingrowth in the canine femora was observed in all implants, with and without HA, at both time periods under backscattered SEM. The mean extent of bone ingrowth at 4 weeks for no-HA, P-HA, and PS-HA implants was 41.5% (95% CI 32.5 to 50.6), 51.0% (95% CI 45.2 to 56.8) and 53.2% (95% CI 41.6 to 64.7), respectively. The mean extent of bone ingrowth at 12 weeks for no-HA, P-HA, and PS-HA implants was 64.4% (95% CI 61.5 to 67.3), 59.9% (95% CI 51.9 to 67.8) and 64.9% (95% CI 58.2 to 71.6), respectively. There was no significant difference in the amount of bone ingrowth between the HA and non-HA coated implants at any of the time points. All the implants were successfully pushed out after 4 weeks of implantation. The mean shear strength from the push-out test at 4 weeks for the no-HA, P-HA, and PS-HA implants was calculated to be 21.6 MPa (95% CI 17.2 to 26.0), 20.7 MPa (95% CI 18.9 to 22.4), and 20.2 MPa (95% CI 16.3 to 24.2), respectively. At week 12, in two femora all three implant types had compressive failure before rupture of the bone-implant interface with a load of over 2000N. This suggests that the values of shear strength were higher than those calculated from the successful tests at 12 weeks. The mean shear strength for the remaining no-HA, P-HA and PS-HA implants at 12 weeks was calculated to be 39.9 MPa (95% CI 29.8 to 50.9), 33.7 MPa (95% CI 26.3 to 41.2), and 36.0 MPa (95% CI 29.53 to 42.4), respectively. For all implants, the mean shear strength at 12 weeks was statistically significantly greater than at 4 weeks (p<0.05). There was no significant difference in the shear strength between HA coated and non-HA coated implants at 4 or 12 weeks. Conclusion. At 4 and 12 weeks, all non-HA coated LRM Ti6Al4V implants consistently exhibited very high bone ingrowth and mechanical shear strength in the canine model. These results demonstrate that this novel additive manufactured porous implant promoted biological fixation in a canine model. There was no significant improvement in the extent of bone ingrowth with the addition of HA. This is in agreement with the literature indicating that topography is the dominant factor governing bone apposition to hydroxyapatite-coated implants. It is likely that in this model, the morphologic features and roughness of the surface of the LRM implants stimulated osteoblastic activity, so that the addition of HA had a non-significant effect

Introduction. As new innovations are developed to improve the longevity of joint replacement components, preclinical testing is necessary in the early stages of research into areas such as osseointegration, metal-cartilage wear and periprosthetic joint infection (PJI). Large-animal studies that test load-bearing components are expensive, however, requiring that animals be housed in special facilities that are not available at all institutions. Comparably, small animal models, such as the rat, offer several advantages including lower cost. Load-bearing implants remain difficult to manufacture via traditional methods in the sizes required for small-animal testing. Recent advances in additive manufacturing (3D metal-printing) have allowed for the creation of miniature joint replacement components in a variety of medical-grade metal alloys. The objective of this work is to create and optimize an image-based 3D-printed rat hip implant system that will allow in vivo testing of functional implant properties in a rat model. Methods. A database of n=25 previously-acquired, 154μm micro-CT volumes (eXplore Locus Ultra, GE Medical) of male Sprague-Dawley rats (390–610g) were analyzed to obtain spatial and angular relationships between several anatomical features of the proximal rat femora. Mean measurements were used to guide the creation of a femoral implant template in computer-aided design software (Solidworks, Dassault Systemes). Several different variations were created, including collarless and collared designs, in a range of sizes to accommodate rats of various weights. Initial prototypes were 3D-printed 316L stainless steel with subsequent iterations printed in Ti6Al4V titanium and F75 cobalt-chrome. Implants were post-processed via sandblasting, hand-polishing, ultrasonic bath, and sterilization in an autoclave. Innate surface texturing was left on manufactured stems to promote osseointegration. Surgical implantation was performed in three live Sprague-Dawley rats (900g, 500g, 750g) with preservation of muscle attachments to the greater trochanter. Micro-CT imaging and X-ray fluoroscopy were performed post-operatively on each animal at 1 day, and 1, 3, 9 and 12 weeks to evaluate gait and component positioning. Results. Implantation of components was successful and each animal was observed to ambulate on its affected limb immediately following recovery from surgery. The 900g rat, given a collarless 316L stainless steel component, was kept for 11 months post-implantation before succumbing to old age. Micro-CT and fluoroscopic findings revealed no evidence of implant subsidence. The 500g animal, given a collarless 316L stainless steel implant, showed evidence of implant subsidence at 3 weeks, with full subsidence and hip dislocation at 12 weeks. The 750g rat, given a collared F75 cobalt-chrome implant, was observed ambulating on its affected limb, but experienced implant rotation and failure at 9 weeks. Conclusions. We report the first hip hemi-arthroplasty in a rat using a 3D-printed metal implant. This model aims to provide a low-cost platform for studying osseointegration, metal-cartilage interactions, and PJI using a functional, loaded implant. Efforts to further optimize the surgical approach will be made to reduce early implant loosening. A study with larger sample sizes is needed to determine if implants can be installed repeatedly, without complications, before the utility of this approach can be validated. Future work will include surface preparations on implant stems, with micro-CT to longitudinally track changes at the bone-metal interface, and gait analysis on a radiolucent treadmill to quantify post-operative kinematics

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This study aimed to assess the carbon footprint associated with total hip arthroplasty (THA) in a UK hospital setting, considering various components within the operating theatre. The primary objective was to identify actionable areas for reducing carbon emissions and promoting sustainable orthopaedic practices.

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Custom triflange acetabular components (CTACs) play an important role in reconstructive orthopaedic surgery, particularly in revision total hip arthroplasty (rTHA) and pelvic tumour resection procedures. Accurate CTAC positioning is essential to successful surgical outcomes. While prior studies have explored CTAC positioning in rTHA, research focusing on tumour cases and implant flange positioning precision remains limited. Additionally, the impact of intraoperative navigation on positioning accuracy warrants further investigation. This study assesses CTAC positioning accuracy in tumour resection and rTHA cases, focusing on the differences between preoperative planning and postoperative implant positions.

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Custom-made partial pelvis replacements (PPRs) are increasingly used in the reconstruction of large acetabular defects and have mainly been designed using a triflange approach, requiring extensive soft-tissue dissection. The monoflange design, where primary intramedullary fixation within the ilium combined with a monoflange for rotational stability, was anticipated to overcome this obstacle. The aim of this study was to evaluate the design with regard to functional outcome, complications, and acetabular reconstruction.

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The aim of this study was to examine the implant accuracy of custom-made partial pelvis replacements (PPRs) in revision total hip arthroplasty (rTHA). Custom-made implants offer an option to achieve a reconstruction in cases with severe acetabular bone loss. By analyzing implant deviation in CT and radiograph imaging and correlating early clinical complications, we aimed to optimize the usage of custom-made implants.