Polyethylene wear is a significant factor limiting survivorship of total knee arthroplasty (TKR). Crosslinking of polyethylene has been shown to significantly reduce wear in hip arthroplasty but has not been reported for TKR. This study measured wear in polyethylene cross-linked to two levels in a knee wear simulator. Six polyethylene knee inserts were tested in a knee wear simulator. Inserts were manufactured from polyethylene crosslinked to two different levels: 2.5 Mrad (Low-X) and 10.5 Mrad (High-X). Each implant was enclosed in a closed lubricant (50% alpha fraction calf serum) recirculation chamber, maintained at 37°C and changed every 500,000 cycles. Physiologic levels of load and motion were applied at 1 Hz for a total of 6,000,000 cycles. Wear was measured by the gravimetric method before wear testing and at every 500,000 cycles. Semi-quantitative wear assessment was performed by imaging the insert surfaces at 10x magnification. The Low-X inserts demonstrated significantly higher wear rates (mean 4.66 mg/million cycles) than the High-X inserts (mean 1.55 mg/million cycles, p < 0.001). Wear scars on the Low-X inserts were irregular and visibly deeper than those on the High-X inserts. The machining marks on the surface of the insert were also better preserved in the High-X insert wear scars. These results suggest that crosslinked PE can significantly reduce wear in TKR under physiologic conditions. This can result in reduced lysis and increased survivorship. Localized damage can cause catastrophic failure in polyethylene knee inserts. Therefore, further studies are necessary to evaluate wear under these conditions

INTRODUCTION

Wear and polyethylene damage have been implicated in up to 22% of revision surgeries after unicompartmental knee replacement. Two major design rationales to reduce this rate involve either geometry and/or material strategies. Geometric options involve highly congruent mobile bearings with large contact areas; or moderately conforming fixed bearings to prevent bearing dislocation and reduce back-side wear, while material changes involve use of highly crosslinked polyethylene. This study was designed to determine if a highly crosslinked fixed-bearing design would increase wear resistance.

Polyethylene (PE) wear affects survivorship in the long term while dislocation remains a significant factor in the short term. Increasing head size can reduce impingement and dislocation. However, this increases wear rates and reduces the net thickness of the liner. Several reports have demonstrated significant reduction in wear in cross-linked PE. This study reports wear rates in crosslinked PE liners with increased head size. Four groups of PE liners were tested against cobalt-chrome heads in a hip wear simulator: highly crosslinked liners with head size 28mm (28XPE) and 32mm (32XPE), and minimally crosslinked liners with head size 28mm (28PE) and 32mm (32PE). Additional liners were used as load-soak controls to monitor weight gain due to fluid absorption. Gravimetric analysis was performed every 500,000 cycles for a total of 5,000,000 cycles. 28PE and 32PE liners had mean wear rates of 12.5(±1.0) and 17.45 (±2.6) mg/million cycles. Both highly crosslinked PE liners (28XPE and 32XPE) had significant less wear rates that regular polyethylene 1.49 (±0.72) and 2.55 (±0.19) mg/million cycles respectively. Increasing head size resulted in increased wear, which is consistent with previous reports. Highly crosslinked PE significantly reduced wear rates in both head sizes. Although there was a small increase in wear in the 32XPE group compared to the 28XPE group, wear was significantly less than both 32PE and 28PE groups. These encouraging results suggest that a dual benefit (reduced wear and reduced dislocation rate) might be achieved using 32XPE liners. Further studies that evaluate fatigue damage, crack propagation and impingement are necessary.

Increasing crosslinking has been shown in vitro and in vivo to markedly improve the wear resistance of ultra-high molecular weight polyethylene (UHMWPE). However, the reduction in the mechanical properties of polyethylene under certain methods used to produce crosslinking has been a concern. These reductions are known to result from the processes used to increase the crosslink density and could affect the device performance in vivo. We present a novel method of increasing the crosslink density of UHMWPE in which UHMWPE is irradiated in air at an elevated temperature with a high dose rate electron beam and is subsequently melt-annealed. This treatment markedly improves the wear resistance of the polymer as tested in a hip simulator while maintaining the mechanical properties of the material within national and international standards. This method also leads to the absence of detectable free radicals in the polymer and, as a result, excellent resistance to oxidation of the polymer.

Remelted highly cross linked UHMWPEs have no detectable free radicals but the mechanical and fatigue properties are reduced because remelting changes the microstructure. Annealed highly cross linked UHMWPEs maintain the microstructure and mechanical properties but contain free radicals. A novel sequential irradiation and annealing process preserves the microstructure while providing enhanced oxidation resistance.

6_B_Material_e_Methods: GUR 1020 polyethylene was sequentially cross linked using three separate gamma radiation doses of 3 Mrad with an annealing step at 130 degrees C after each irradiation (SXL). Density was measured according to ASTM D1505. Crystallinity and thermal properties were determined according to ASTM D3417. Crystallite size/lamellar structure was determined by small angle x-ray scattering. Accelerated aging was carried out in an oxygen bomb under 5 atmospheres of oxygen at 70 degrees C for 14 days.

SXL density was 939.2 kg/cubic meter, identical to that for unirradiated UHMWPE and UHMWPE irradiated in nitrogen to 3 Mrad (gamma-N2). SXL crystallinity was 61.7%, compared to 61.3% and 59.2% for gamma-N2 and virgin UHMWPE, respectively. The long period spacing, crystal thickness and amorphous thickness were 38.2, 23.6 and 14.6 nm respectively for SXL and 38.9, 23.0 and 15.9 for gamma-N2. There was no statistical difference. Accelerated aging resulted in a white band for gamma-N2 with an oxidation index of 1.27. The response of SXL was the same as virgin UHMWPE e.g. crystallinity and density were unchanged with no white band formation and an oxidation index of 0.09.

By avoiding remelting, sequential irradiation and annealing preserves polyethylene microstructure. The sequential process allows more efficient cross linking of free radicals resulting in an oxidation resistance equivalent to that of virgin UHMWPE.

INTRODUCTION

Electron-beam-irradiated dl-α-Tocopherol (Vitamin E)-blended UHMWPE is now being considered as a potential new bearing surface material for hip prosthesis [1]. However, Vitamin E stabilizes some of the primary free-radicals required for crosslinking, thereby reducing the material's crosslink density [2]. Additionally, some biological-stabilization effects of Vitamin E may also be reduced by oxidation. In this study, Vitamin E radicals in electron-beam-irradiated UHMWPE were measured and identified using Electron Spin Resonance (ESR), and the effects of annealing on radical stabilization and crosslink density were examined.

Aims

To investigate the effect of polyethylene manufacturing characteristics and irradiation dose on the survival of cemented and reverse hybrid total hip arthroplasties (THAs).

The aim of this work was the structural investigation of different type I collagen isoforms at atomic and nanoscale, as well as the evaluation of the impact of different fabrication treatments on the structural, mechanical and biological properties of collagen-based films. Raw type-I collagens from bovine hide (Typ-BH, CS, SYM) and equine tendon (TypE, TypCH and OPO) were analyzed. Materials were then used for fabricating air-dried films, obtained by: 1) dissolution in distilled water (HH); 2) dissolution in acidic medium (AA); 3) homogenization of acid solubilized fibers (HOM). Crosslinking treatments (DHT, DHT+EDC) were also adopted and studied. Analysis by Wide Angle (WAXS) and Small Angle (SAXS) X-ray Scattering was carried out at the XMI L@b (CNR-IC-Bari); Fourier Transform-IR and biological analysis was performed at UniSalento. WAXS and SAXS data on raw materials demonstrated the preferential orientation of collagen molecules and the preservation of hierarchical nanoscale architecture in equine tendon-derived collagens, in particular in chemically extracted, while randomly oriented molecules were found in bovine dermis collagens, together with a certain degree of salt contamination. Concerning equine collagen, we found that TypCH structure is influenced by crosslinking procedures at atomic scale, whereas both processing conditions and crosslinking treatments affect TypE collagen structure at atomic and nanoscale. WAXS, SAXS and FT-IR analyses showed that the HOM processing was the one which ensures a high content of structural super-organization of collagen into triple helices and a high crystalline domainof the final material. Crosslinking of the films by DHT/EDC combined treatment was shown to affect their mechanical stiffness, the latter depending on the collagen source and the specific processing conditions

Crosslinking has been already used for about 80 years to enhance the longevity of polyethylene cables. The polymer alteration has been achieved with peroxide, silane or irradiation. The medical devices industry discovered the benefit of this technology for its tribological applications like hip or knee bearings in the 2000s as crosslinking improves considerably the abrasion resistance of the material. The more current methods used are Gamma and Beta irradiation. On the basis of economical (rising prices of Cobalt), environmental (the radioactive source can not be turned off), technological (low dose rate) drawbacks for Gamma respectively low penetration for Beta irradiation we decided to investigate an alternative technology: the X-Ray irradiation, which provides a homogeneous crosslinking in a relatively short time. We analyzed the wear, mechanical, thermal, oxidative and network properties of two vitamin E doped UHMWPE: first crosslinked with E-Beam, second with X-Ray. There wasn't any significant difference between the X-Ray and the E-Beam crosslinked material

Background. Wear and fatigue damage to polyethylene components remain major factors leading to complications after total knee and unicompartmental arthroplasty. A number of wear simulations have been reported using mechanical test equipment as well as computer models. Computational models of knee wear have generally not replicated experimental wear under diverse conditions. This is partly because of the complexity of quantifying the effect of cross-shear at the articular interface and partly because the results of pin-on-disk experiments cannot be extrapolated to total knee arthroplasty wear. Our premise is that diverse experimental knee wear simulation studies are needed to generate validated computational models. We combined five experimental wear simulation studies to develop and validate a finite-element model that accurately predicted polyethylene wear in high and low crosslinked polyethylene, mobile and fixed bearing, and unicompartmental (UKA) and tricompartmental knee arthroplasty (TKA). Methods. Low crosslinked polyethylene (PE). A finite element analysis (FEA) of two different experimental wear simulations involving TKA components of low crosslinked polyethylene inserts, with two different loading patterns and knee kinematics conducted in an AMTI knee wear simulator: a low intensity and a high intensity. Wear coefficients incorporating contact pressure, sliding distance, and cross-shear were generated by inverse FEA using the experimentally measured volume of wear loss as the target outcome measure. The FE models and wear coefficients were validated by predicting wear in a mobile bearing UKA design. Highly crosslinked polyethylene (XLPE). Two FEA models were constructed involving TKA and UKA XLPE inserts with different loading patterns and knee kinematics conducted in an AMTI knee wear simulator. Wear coefficients were generated by inverse FEA. Results. Predicted wear rates were within 5% of experimental wear rates during validation tests. Unicompartmental mobile bearing back-side wear accounted for 46% of the total wear in the mobile bearing. Wear during the swing phase was 38% to 44% of total wear. Discussion & Conclusions. Crosslinking polyethylene primarily decreased (by nearly 10-fold) the wear generated by cross-shear. This result can be explained by the reduced propensity of crosslinked polyethylene molecules to orient in the dominant direction of sliding. A highly crosslinked fixed-bearing polyethylene insert can provide high wear performance without the increased risk for mobile bearing dislocation. Finite element analysis can be a robust and efficient method for predicting experimental wear. The value of this model is in rapidly conducting screening studies for design development, assessing the effect of varying patient activity, and assessing newer biomaterials. This FEA model was experimentally validated but requires clinical validation

Purpose:. Crosslinking of polyethylene has become synonymous with longevity in total hip replacement. In the USA 70–85% of all polyethylene cups underwent crosslinking since 2008. Three publications appeared in the autumn 2011 volume of the “SA Orthopaedic Journal,” on the 10–33 year follow-up of the original SA crosslinked implant. The purpose of this study is to illustrate and confirm statistically, the improvement of the bone cement interface, provided that wear of polyethylene can be reduced to an absolute minimum. Method:. Complete follow-up included Merle D'Aubigne clinical follow-up and radiological studies of the interface. Interpretation of radiological measurements was according to the D.M. (Digital Magnification) method, as published in 2007. This information was digitally analysed by the Department of Statistics, University of Pretoria. Follow-up was at six months post op and again at end of study. All cups were crosslinked with fixed-dose Gamma-rays, in a saturated acetylene environment, acting as mediating gas. This resulted in enhanced crosslinking in the superficial 300µ of the pre-manufactured implant. Result:. Of the 97 cases studied, 58 showed no interface changes at all, while 26 cases had deteriorated moderately and of which only 7 cases needed revision as result of polyethylene wear of >1 mm. The correlation between wear and interface deterioration was statistically proven with excellent p-values. Most interesting was the third group of 16 cases (16.6%) that also showed no cup wear, but additionally displayed definite radiological signs of interface improvement. Conclusion:. We conclude that the correlation between cup wear and interface deterioration is well proven and documented in this study. We can now state with confidence that polyethylene wear has to be minimised at all cost. Improvement of the interface is a new phenomenon which can only be achieved under extremely low wear conditions, and promises excellent longevity of the arthroplasty

Crosslinking of UHMWPE markedly improves its wear resistance. However, Green et al. (JBMR 53, 490, 2000) have reported that the wear debris from crosslinked PE were smaller than from non-crosslinked PE, and that particles with a mean diameter of 0.24 μm diameter caused more osteolytic activity of mouse macrophages in vitro than 0.45 μm or 1.7 μm particles. In order to predict how a new PE will behave clinically, however, it is desirable to compare its particle morphology to that of the gamma-air sterilized PE that was used in the vast majority of acetabular cups over the past three decades. We compared PE wear debris that were generated in a hip simulator and recovered by digestion and filtration of the serum lubricants, from cups crosslinked at 2.7 Mrads in air (historical controls), and cups machined from extruded bars that had been pre-gamma crosslinked at 4.5 Mrads and remelted (to extinguish free radicals and stabilize against oxidation) prior to cup machining. The debris were 85% and 92% rounded particles, respectively, and the balance were fibrils. The diameters of most of the rounded particles were from 0.07 to 0.3 μm, with very similar distributions in this range for the two materials. The total number of round particles from the 4.5 Mrad remelted PE was 32% and 76% below that of the 2.7 Mrad gamma-air non-aged and aged cups, respectively, the number of fibrils was 66% and 88% lower, respectively, and the total volume of wear debris per million cycles was 71% and 90% lower with the 4.5 Mrad-remelted PE cups, respectively. Since there was little if any systematic change in particle morphology, the substantially reduced wear and high oxidation resistance of the cups fabricated from gamma crosslinked-remelted PE could markedly reduce the incidence of clinical osteolysis

Aims

The primary objective of this study was to compare the five-year tibial component migration and wear between highly crosslinked polyethylene (HXLPE) inserts and conventional polyethylene (PE) inserts of the uncemented Triathlon fixed insert cruciate-retaining total knee arthroplasty (TKA). Secondary objectives included clinical outcomes and patient-reported outcome measures (PROMs).

Introduction: Crosslinking has been extensively introduced to reduce the wear of UHMWPE. Zero wear of highly crosslinked UHMWPE has been reported by some groups (. 1. ) in hip simulators, clinical studies have reported finite wear rates (. 2. ). The aim of this study was to compare the wear rates produced by UHMWPE with different levels of crosslinking. Materials and Methods: Studies were carried out using 28mm diameter cobalt chrome femoral heads. These were articulated against UHMWPE in the Leeds ProSim hip joint simulator. The acetabular cups were manufactured from UHMWPE GUR 1050. The GUR 1050 was highly crosslinked with 10MRad or 7.5MRad of gamma irradiation in nitrogen followed by re-melting at a temperature above 150°C. Slightly crosslinked GUR 1050 was also tested (gamma irradiated with 2.5MRad in air). Non-crosslinked GUR 1050 UHMWPE was used as a control. Five cups of the materials were tested with one station from each set of five being used for creep data. Wear measurements were taken every million cycles using a coordinate measuring machine and tests were run to 5 million cycles. The tests were carried out in low serum concentrations of 25% (v/v) bovine serum diluted with 0.1% (w/v) sodium azide in water. At each million cycles a 3D measurement was taken of the contact region of the acetabular cups using a Form Talysurf profilometer. Results and Discussion: The wear rate decreased as crosslinking levels increased. The non-crosslinked material had an overall average wear (mm3/million cycles) determined by volume change of 45.6+/−1.35, the 2.5MRad material 46.9+/−9.4, the 7.5MRad 15.04+/−4.28 and the 10MRad material 8.7+/−3.11. The intentionally cross-linked materials showed a significantly lower volume change than the other two materials, with the 10MRad polyethylene having a slightly lower volume change than the 7.5MRad polyethylene. All four polyethylenes showed greater volume change in the first million cycles than the subsequent four and this was associated with initial creep deformation in the first million cycles. The individual creep deformation cups confirmed this with volume changes in the first million cycles followed by stability. Creep volumes of between 10 and 25 mm3 total were measured with the lowest value being for the 10MRad polyethylene. The steady state wear rates for the PE’s between one and five million cycles were 0MRad 36.9+/−1.92 mm3/million cycles, 2.5MRad 44.12+/−10.09, 7.5MRad 7.89+/−2.32 and 10MRad 4.62+/−2.73. The results of the surface topography of the acetabular cups showed that the highly crosslinked materials became smoother than the other materials as the test progressed. This would benefit the crosslinked materials in aiding lubrication and could have contributed to the lower wear rate seen with these materials. Conclusion: The highly crosslinked UHMWPE gave lower wear volumes than the noncrosslinked materials. This could have been due to the smoother surfaces of the cups as the study progressed which resulted in better lubrication of the components. Finite wear rates have been recorded for the first time with highly cross-linked polyethylene, that compare with clinical observations

Objectives

Unicompartmental knee arthroplasty (UKA) is an alternative to total knee arthroplasty with isolated medial or lateral compartment osteoarthritis. However, polyethylene wear can significantly reduce the lifespan of UKA. Different bearing designs and materials for UKA have been developed to change the rate of polyethylene wear. Therefore, the objective of this study is to investigate the effect of insert conformity and material on the predicted wear in mobile-bearing UKA using a previously developed computational wear method.

Aims

The aim of this study was to identify the effect of the manufacturing characteristics of polyethylene acetabular liners on the survival of cementless and hybrid total hip arthroplasty (THA).

Advances in polyethylene (PE) in total hip arthroplasty have led to interest and increased use of highly crosslinked PE (HXLPE) in total knee arthroplasty (TKA). Biomechanical data suggest improved wear characteristics for HXLPE inserts over conventional PE in TKA. Short-term results from registry data and few clinical trials are promising. Our aim is to present a review of the history of HXLPEs, the use of HXLPE inserts in TKA, concerns regarding potential mechanical complications, and a thorough review of the available biomechanical and clinical data.

Cite this article: Bone Joint J 2017;99-B:996–1002.

Aims

The aim of this study was to evaluate the surface damage, the density of crosslinking, and oxidation in retrieved antioxidant-stabilized highly crosslinked polyethylene (A-XLPE) tibial inserts from total knee arthroplasty (TKA), and to compare the results with a matched cohort of standard remelted highly crosslinked polyethylene (XLPE) inserts.

Aims

The primary aim of this study was to compare the wear properties of vitamin E-diffused, highly crosslinked polyethylene (VEPE) and one formulation of moderately crosslinked and mechanically annealed ultra-high molecular weight polyethylene (ModXLPE) in patients five years after primary total hip arthroplasty (THA). The secondary aim was to assess the clinical results of patients treated with VEPE by evaluating patient-reported outcome measures (PROMs), radiological evidence of fixation, and the incidence of mechanical failure.

Objectives

Ubiquitin E3 ligase-mediated protein degradation regulates osteoblast function. Itch, an E3 ligase, affects numerous cell functions by regulating ubiquitination and proteasomal degradation of related proteins. However, the Itch-related cellular and molecular mechanisms by which osteoblast differentiation and function are elevated during bone fracture repair are as yet unknown.