Aims. Due to their radiolucency and favourable mechanical properties, carbon fibre nails may be a preferable alternative to titanium nails for oncology patients. We aim to compare the surgical characteristics and short-term results of patients who underwent intramedullary fixation with either a titanium or carbon fibre nail for pathological long-bone fracture. Methods. This single tertiary-institutional, retrospectively matched case-control study included 72 patients who underwent prophylactic or therapeutic fixation for pathological fracture of the humerus, femur, or tibia with either a titanium (control group, n = 36) or carbon fibre (case group, n = 36) intramedullary nail between 2016 to 2020. Patients were excluded if intramedullary fixation was combined with any other surgical procedure/fixation method. Outcomes included operating time, blood loss, fluoroscopic time, and complications. Fisher’s exact test and Mann-Whitney U test were used for categorical and continuous outcomes, respectively. Results. Patients receiving carbon nails as compared to those receiving titanium nails had higher blood loss (median 150 ml (interquartile range (IQR) 100 to 250) vs 100 ml (IQR 50 to 150); p = 0.042) and longer fluoroscopic time (median 150 seconds (IQR 114 to 182) vs 94 seconds (IQR 58 to 124); p = 0.001). Implant complications occurred in seven patients (19%) in the titanium group versus one patient (3%) in the carbon fibre group (p = 0.055). There were no notable differences between groups with regard to operating time, surgical wound infection, or survival. Conclusion. This pilot study demonstrates a non-inferior surgical and short-term clinical profile supporting further consideration of carbon fibre nails for pathological fracture fixation in orthopaedic oncology patients. Given enhanced accommodation of imaging methods important for oncological surveillance and radiation therapy planning, as well as high tolerances to fatigue stress, carbon fibre implants possess important oncological advantages over titanium implants that merit further prospective investigation. Level of evidence: III, Retrospective study. Cite this article: Bone Jt Open 2022;3(8):648–655

The soft tissue response to carbon fibre was studied histologically one and a half years after being used to reconstruct the lateral collateral ligament of the human knee. A remarkably consistent pattern was seen in the induced ligament. The basic pattern was a "composite unit", consisting of a core of carbon fibre enveloped in a concentric manner by coherent layers of fibroblasts and collagen fibres. This new structure seemed to have been induced by continuous irritation caused by the physical structure of the carbon fibres; it is unlikely ever to acquire the structure of a natural ligament. However, it is biologically compatible and is biomechanically sufficient as long as the entire tow of carbon fibres is preserved

A radiological and histological analysis of five knee joints after a minimum of 15 years following the implanting of carbon fibre which had been used as a treatment for knee instability was undertaken. All patients underwent Total Knee replacement for secondary osteoarthritis. Histological analysis demonstrated a variable amount of macroscopically visible carbon particles in the synovium, hyaline cartilage and menisci showed . At microscopy these particles were found enveloped by giant cells and lying quiescent with no active inflammatory changes. No intact carbon fibre ligament was noted within the joint, small portion of the old ligament were covered with a thin fibrous layer but there was no evidence of any structure resembling neo-ligament. Extra articularly the carbon fibre was covered with a thick fibrous sheath with no active inflammatory changes inflammation. In the bone tunnels the carbon fibre- bone interface showed an apposition of the bone to the carbon fibre without any interposing fibrous sheath. The histology suggests that carbon fibre bonds directly with the bone without fibrous interposition and that there is no evidence of synovitis changes related to the carbon fibre material. The study suggest that although carbon fibre failed structurally as a ligament replacement it did not cause any significant long term inflammatory pathology

Carbon fibre reinforced polyetheretherketone (CFR-PEEK) has been introduced recently as an alternative material to be used in joint prostheses. During injection moulding of the CFR-PEEK the carbon fibres tend to become orientated in the direction of the plastic flow. The direction of these fibres may affect the wear produced by these materials. Reciprocation only and reciprocation plus rotation (multi-directional) pin-on-plate wear tests were performed on PAN-based CFR-PEEK against itself. The plates were manufactured with the carbon fibres mainly orientated either longitudinally (in the direction of reciprocation motion) or mainly transversally (perpendicular to the direction of motion) to determine the effect of carbon fibre orientation on the wear of these materials. For each test, four pin and plate samples were tested (two reciprocation only and two reciprocation plus rotation) for three and a half million cycles at a cycle frequency of 1 Hz under a 40 N load (which resulted in a contact stress of about 2 MPa). The lubricant used was bovine serum diluted with de-ionised water to a protein content of 17 gl-1. This was maintained at 37 °C. The wear was determined gravimetrically. Soak control specimens were used to account for any weight changes due to lubricant absorption. The average steady-state wear for the CFR-PEEK samples that underwent reciprocation motion only was found to be 5.41 and 18.7 × 10-8 mm3N-1m-1 for the longitudinal carbon fibres and the transverse fibres respectively. For the multi-directional tests, the average steady-state wear was 5.88 and 19.9 × 10-7 mm3N-1m-1 for the longitudinal and transverse fibres respectively. It is clear from these results that for both reciprocation motion only and reciprocation plus rotation the wear was considerably lower with the fibres orientated in the longitudinal direction than the transverse direction. Also, these tests show that reciprocation only gives approximately an order of magnitude lower wear than multi-directional motion. It can be concluded that the wear rate of CFR-PEEK is lower when the sliding motion occurs in the same direction as the carbon fibre orientation. Also, in these pin-on-plate tests, the wear produced using reciprocation motion only was an order of magnitude lower than that for the tests using multi-directional motion. The authors wish to thank INVIBIO Ltd for funding this research

Method: One hundred and twenty-eight knees treated by carbon fibre resurfacing pads and rods for grades III and IV articular cartilage lesions were assessed arthroscopically, with an average follow-up of 22.6 months. The mean age was 37.4 years. Results were scored by an independent observer, using the ICRS scale (1–12) as grade I, normal; grade II, nearly normal; grade III, abnormal; grade IV, severely abnormal. Results: The mean scores were: medial femoral condyle, 10.5; lateral femoral condyle, 9.76; trochlea, 9.9; patella 9.4. Grades I & II scores for rods were: medial femoral condyle, 95.1%; lateral femoral condyle, 76.0%; trochlea, 86.1%; patella, 89.7%. The pads were used in significant numbers only on the patella. Of the total, 76.7% of the repairs were for grades I and II changes. Patellar resurfacing was combined with realignment and an ‘anteriorisation’ procedure in 77 knees. We found that 96.7 % of repairs for grades I & II disease were seen with rods on the patella, when combined with a mechanical correction, compared with 66.0%, when used on the patella without a realignment procedure. However, when the use of pads was combined with mechanical corrections the score was 76% and a lower proportion were grade I repairs (13%) than with rods (30.0%). The mean Waddell Score (0–4) was 2.9. From the survey 81.8% regarded the procedure as worthwhile and 9.1% were doubtful. Conclusions: We concluded that carbon fibre resurfacing was an effective method of treating articular cartilage defects. Rods were more effective than pads and are recommended as the universal method. The results were improved by the correction of abnormal biomechanical alignment. Stabilisation of the cartilage defects resolved synovitis

The anterior cruciate ligament was replaced in rabbits, using implants of carbon or polyester filaments with known mechanical properties. The biocompatibility of the implants was assessed in detail using light microscopy, and scanning and transmission electron microscopy. Mechanical tests were made of stability, in comparison with normal joints and controls after excision of the ligament. Some carbon fibre implants broke down in vivo, allowing instability; the fragments caused chronic inflammation. Intact carbon implants did not induce the formation of neoligaments; they were covered by tissue, but there was no ingrowth. Polyester did not degrade mechanically and supported early collagenous ingrowth within the implant, even in the mid-joint space. It was concluded that there was no justification for the use of carbon fibres as anterior cruciate replacements; polyester appeared to be suitable

Sixty-three knees with chronic ligamentous instability treated with flexible carbon fibre are reviewed. Assessment was by pre-operative and postoperative grading of function in work and sport, together with a subjective evaluation of the result based on stability. Fifteen knees had collateral repairs, seven had cruciate repairs and 41 had combined collateral and cruciate repairs. Overall, 71% of knees showed improvement in function and 67% had good or excellent results subjectively. Clinical examination did not correlate well with the patient's evaluation of the result. Nineteen unselected cases with intra-articular (cruciate) carbon fibre had arthroscopies. Infiltration of collagen tissues into the cruciate replacement was a slower process than at the extra-articular (collateral) site. There was no clinical or macroscopic evidence of synovitis but microscopically there was evidence of synovial irritation

Our purpose was to determine whether continuous passive motion enhanced the quality of knee ligament reconstruction using carbon fibre. In 46 rabbits the medial collateral ligaments were excised and replaced with carbon fibre prostheses. The animals were treated postoperatively by either continuous passive motion, cast immobilisation or cage activity, termed intermittent active motion. At six weeks, the ligaments were compared histologically and biomechanically with normal (control) medial collateral ligaments and with sham-operated controls. The ligaments treated with continuous passive motion were superior to those in the other two treatment groups. There were no ligament failures in any of the groups. This study suggests that continuous passive motion, initiated immediately postoperatively, enhances the biomechanical properties of carbon fibre ligament replacement of the medial collateral ligament while preventing the harmful effects of joint immobilisation

Ruptures of the calcaneal tendon which present late may be repaired using carbon fibre to induce a neotendon. The operative technique is described and the results of five cases reviewed. The average muscle power obtained was 88% of normal, and the thickness of the neotendon was 148% of that of the normal side. It would appear that this tendon formation in man is comparable to that previously described in sheep

We compared the mechanical properties of carbon fibre composite bone plates with those of stainless steel and titanium. The composite plates have less stiffness with good fatigue properties. Tissue culture and small animal implantation confirmed the biocompatibility of the material. We also present a preliminary report on the use of the carbon fibre composite plates in 40 forearm fractures. All fractures united, 67% of them showing radiological remodelling within six months. There were no refractures or mechanical failures, but five fractures showed an unexpected reaction; this is discussed

Carbon fibre appears to induce the formation of tendon in both animals and humans. Experiments have been conducted in sheep in which new anterior cruciate ligaments have been induced in response to the implantation of filamentous carbon fibre. Long-term studies indicate that the carbon fibre slowly breaks up at the site of implantation and later begins to appear in the regional lymph nodes

We assessed the use of woven carbon fibre pads to resurface osteochondral defects in animals and in patients. The pads became filled with structurally strong and compliant fibrous tissue and did not provoke a synovial reaction, though pigmentation was induced in some animals. Of the patients, 77% had a satisfactory response to resurfacing, with no synovitis. Our initial experiments indicate that carbon pads may provide a satisfactory treatment for localised articular defects

Knee arthroplasty with a rotating hinge knee (RHK) prosthesis has become an important clinical treatment option for knee revisions and primary patients with severe varus or valgus deformities and instable ligaments. The rotational axle constraints the anterior-posterior shear and varus-valgus moments, but currently used polyethylene bushings may fail in the mid-term due to insufficient creep and wear resistance of the material. Due to that carbon-fibre-reinforced (CFR) PEEK as an alternativ bushing material with enhanced creep, wear and fatigue behaviour has been introduced in a RHK design [Grupp 2011, Giurea 2014]. The objective of our study was to compare results from the pre-clinical biotribological characterisation to ex vivo findings on a series of retrieved implants.

In vitro wear simulation according to ISO 14243-1 was performed on rotating hinge knee devices (EnduRo® Aesculap, Germany) made out of cobalt-chromium and of a ZrN multi-layer ceramic coating for 5 million cycles. The mobile gliding surfaces were made out of polyethylene (GUR 1020, β-irradiated 30 ± 2 kGy). For the bushings of the rotational and flexion axles and the flanges a new bearing material based on CFR-PEEK with 30% PAN fiber content was used.

Analysis of 12 retrieved EnduRo^® RHK systems in cobalt-chromium and ZrN multi-layer in regard to

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loosening torques in comparison with initial fastening torques

with a focus on the four CFR-PEEK components integrated in the EnduRo^® RHK design.

For the rotating hinge knee design with flexion bushing and flanges out of CFR-PEEK the volumetric wear rates were 2.3 ± 0.48 mm³/million cycles (cobalt-chromium) and 0.21 ± 0.02 mm³/million cycles (ZrN multi-layer), a 10.9-fold reduction (p = 0.0016). The UHMWPE and CFR-PEEK particles were comparable in size and morphology and predominantly in submicron size [5]. The biological response to representative sub-micron sized CFR-PEEK particles has been demonstrated in vivo based on the leucoyte-endothelian-cell interactions in the synovia of a murine intra-articular knee model by Utzschneider 2010. Schwiesau 2013 extracted the frequency of daily activities in hip and knee replacement patients from literature and estimated an average of 1.76 million gait cycles per year. Thus, the 5 million cycles of in vitro wear testing reflect a mean in vivo service life of 2.9 years, which fits to the time in vivo of 12–60 months of the retrieved RHK devices. The in vitro surface articulation pattern of the wear simulation tests are comparable to findings on retrieved CFR-PEEK components for both types of articulations – cobalt-chromium and ZrN multi-layer coating.

For the rotating hinge knee design the findings on retrieved implants demonstrate the high suitability of CFR-PEEK as a biomaterial for highly loaded bearings, such as RHK bushings and flanges in articulation to cobalt-chromium and to a ZrN multi-layer coating.

Posterior lumbar interbody fusion is a well described procedure for the treatment of back pain associated with degenerative disc disease and segmental instability. It allows decompression of the spinal canal and circumferential fusion through a single posterior incision.

Sixty-five consecutive patients who underwent posterior lumbar interbody fusion (PLIF) using carbon cages and pedicle fixation between 1993 and 2000 were recruited and contacted with a postal survey.

Clinical outcome was assessed by the assessment of postoperative clinical findings and complications and the fusion rate, which was assessed using standard X-rays with the scoring system described by Brantigan and Steffee. Functional outcome was measured by using improvement in the Oswestry Disability Index, PROLO score, return to work and satisfaction with the surgical outcome. The determinants of functional relief were analysed against the improvement in disability using multiple regression analysis.

The mean postoperative duration at the time of the study was 4.4 years. The response rate to the survey was 84%. Overall radiological fusion rate was ninety eight percent. There was a significant improvement in Oswestry Disability Index P< 0.001. There was 85% satisfaction with the surgical procedure and 58% return to pre-disease activity level and full employment. In the presence of near total union rate we found preoperative level of disability to be best the determinant of functional recovery irrespective of age or the degree of psychological morbidity (p< 0.0001).

The combination of posterior lumbar interbody fusion (PLIF) and posterior instrumented fusion is a safe and effective method of achieving circumferential segmental fusion. This procedure gives sustained long-term improvement in functional outcome and high satisfaction rate. Direct relationship between preoperative level of disability and functional recovery suggests that spinal fusion should be performed to alleviate disability caused by degenerative spine.

The aim of this study is to assess the success of posterior lumbar interbody fusion in the treatment of degenerative spinal instability. Methods: Historical prospective study containing sixty-five consecutive patients who underwent posterior lumbar interbody fusion (PLIF) using carbon cages and pedicle fixation between 1993 and 2000.

Clinical outcome was assessed by the postoperative symptomatic relief, complications rate and the fusion rate. The fusion rate was assessed using plain radiographs and the Brantigan and Steffee scoring system. Functional outcome was measured by the improvement in the Oswestry disability index, PROLO score, return to work and satisfaction with the surgical outcome. The determinants of functional relief were analysed against the improvement in disability using multiple regression analysis. Results: Overall fusion rate was ninety eight percent. There was a significant improvement in Oswestry disability index P< 0.001. There was 85% satisfaction with the surgical procedure and 58% return to pre-disease activity level. We found preoperative level of disability to be best the determinant of functional recovery irrespective of age or the degree of psychological morbidity (p< 0.0001). Conclusion: The combination of posterior lumbar interbody fusion (PLIF) and posterior instrumented fusion is a safe and effective method of achieving segmental fusion with sustained functional relief and high satisfaction rate. Direct relationship between preoperative level of disability and functional recovery suggests that spinal fusion should be performed to alleviate disability caused by degenerative spine.

Background. Carbon fibre (CF) instrumentation is known to be radiolucent and has a tensile strength similar to metal. A specific use could be primary or oligometastatic cancer where regular surveillance imaging and Stereotactic Radiotherapy are required. CT images are inherently more prone to artefacts which affect Hounsfield unit (HU) measurements. Titanium (Ti) screws scatter more artefacts. Until now it has been difficult to quantify how advantageous the radiolucency of carbon fibre pedicle screws compared to titanium or metallic screws actually is. Methodology. In this retrospective study, conducted on patients from 2018 to 2020 in SGH, we measured the HU to compare the artifact produced by CF versus Ti pedicle screws and rods implanted in age and sex matched group of patients with oligometastatic spinal disease. Results. Eleven patients were included in each group. We compared the change of HU between preoperative and postoperative cases of both CF & Ti screws, which clearly shows Ti screws scatter lot more artefacts than CF screws. We are proposing a CT artefact grading system from grade 0 to grade 4 based on the percentage change of HU for unequivocal understanding of the CT artefacts. Conclusion. This study clearly shows the artefacts produced by the metallic implants are significantly higher than the carbon fibre implants. Considering the efficacy of the RT and the increased life expectancy as a consequence, carbon instrumentation MAY BE superior to titanium or metallic instrumentation. The artefact grading system will help the clinicians in describing and planning where the artefacts need to be factorized

In case of spine tumors, when en bloc vertebral column resection (VCR) is indicated and feasible, the segmental defect should be reconstructed in order to obtain an immediate stability and stimulate a solid fusion. The aim of this study is to share our experience on patients who underwent spinal tumor en bloc VCR and reconstruction consecutively. En bloc VCR and reconstruction was performed in 138 patients. Oncological and surgical staging were performed for all patients using Enneking and Weinstein-Boriani-Biagini systems accordingly. Following en bloc VCR of one or more vertebral bodies, a 360° reconstruction was made by applying posterior instrumentation and anterior implant insertion. Modular carbon fiber implants were applied in 111 patients, titanium mesh cage implants in 21 patients and titanium expandable cages in 3 patients; very recently in 3 cases we started to use custom made titanium implants. The latter were prepared according to preoperative planning of en bloc VCR based on CT-scan of the patient, using three dimensional printer. The use of modular carbon fiber implant has not leaded to any mechanical complications in the short and long term follow-up. In addition, due to radiolucent nature of this implant and less artifact production on CT and MRI, tumor relapse may be diagnosed and addressed earlier in compare with other implants, which has a paramount importance in these group of patients. We did not observe any implant failure using titanium cages. However, tumor relapse identification may be delayed due to metal artifacts on imaging modalities. Custom- made implants are economically more affordable and may be a good alternative choice for modular carbon fiber implants. The biocompatibility of the titanium make it a good choice for reconstruction of the defect when combined with bone graft allograft or autograft. Custom made cages theoretically can reproduce patients own biomechanics but should be studied with longer follow-up

The tissue surrounding carbon fibre reinforced epoxy resin plates applied to forearm and tibial fractures was biopsied in 32 patients at the time the plates were removed. The reaction was minimal and was compared with that in a control group of 16 similar patients in whom stainless steel plates were used. No significant histological differences were found. A series of experiments on rats, in which the histology was studied from 2 to 78 weeks, also showed that there was very little reaction to carbon fibre reinforced plastic