Fluid film lubricating ability of a total hip prosthesis depends on the profile accuracies including surface-roughness or the sphericity of a head or a cup. Therefore, surface polishing is important. It was, however, difficult to polish the central portion of a cup or head using the conventional rotating machine. In the present study, we developed a polishing method combining a pendulum machine and a robotic arm. The effect of the accuracy improvement by this method was evaluated by the friction measurements on some test specimens. Nine balls and a cup of Co-Cr-Mo alloy that were polished by a conventional process using a rotating machine were prepared for the prototype. The average diameter of the balls was 31.9648 mm with the sphericity of 0.0028 μm. The inside diameter of the cup was 31.9850 mm with the sphericity of 0.0044 μm. We combined a robotic arm and a pendulum apparatus to enable the further polishing. The ability of both automatic centering and change in the sliding direction was accomplished by this system. The sliding direction has been changed 180 times every ten degrees. The total distance of polishing was 120 m under vertical load of 100 N in a bath of saline solution containing abrasive grains of silicate of the diameter of 2μm. The surface roughness of the central portion of the cup, which is important area for the fluid film lubrication decreased from Ra 20.2 μm before the polishing to Ra 18.7 μm after the polishing. A pendulum type friction tester was used for the assessment of the improvement of the lubricating ability by the polishing. The measurement was run over at 10 times under the conditions of the load of 600 N in a bath of saline solution. As the result, the frictional coefficients decreased from 0.1456–0.1720 before polishing to 0.1250–0.1300 after polishing. The polishing effect was, however, observed only at the specimens that radial clearances did not exceed the value of 50 μm. The present results indicated that the surface polishing of the central portion of hip prostheses must improve the lubrication ability and the radial clearance before the finishing process should be chinked as possible

Polyimide (MP-1, MMATech, Haifa, Israel), is a high performance aerospace thermoplastic used for its lubricity, stability, inertness and radiation resistance. A wear resistant thin robust bearing is needed for total hip arthroplasty (THR). After independent laboratory testing, in 2006, the author used the material as a bearing in two Reflection (Smith and Nephew, USA) hip surgeries. The first, a revision for polyethylene wear, survives with no evidence of wear, noise, new osteolysis or complications related to the MP-1 bearing after 16 yrs. The second donated his asymptomatic MP-1 hip at 6.5yrs for post-mortem examination. There were no osteoclasts, cellular reaction bland in contrast to that of polyethylene. In 2013 a clinical study with ethical committee approval was started using a Biolox Delta (Ceramtec, Germany) head against a polyimide liner in 97 patients. MMATech sold all liners, irradiated: steam 52:45. Sixteen were re-machined in New Zealand. Acetabular shells were Delta PF (LIMA, Italy). The liner locked by taper. The cohort consisted of 46:51 M:F, and ages 43 to 85, mean 65. Ten received cemented stems. For contralateral surgery, a ceramic or polyethylene liner was used. Initial patients were lower demand, later, more active patients, mountain-biking and running. All patients have on-going follow up, including MP-1 liner revision cases. There has been no measurable wear, or osteolysis around the acetabular components using weight-bearing radiographs. Squeaking within the first 6 weeks was noted in 39 number of cases and subtle increase in palpable friction, (passive rotation at 50 degrees flexion), but then disappeared. There were 6 revisions, four of which were related to cementless Stemsys implants (Evolutis, Italy) fixed distally with proximal linear lucencies in Gruen zones 1 and 7, and 2 and 6. No shells were revised and MP-1 liners were routinely changed to ceramic or polyethylene. The liners showed no head contact at the apex, with highly polished contact areas. There were no deep or superficial infections, but one traumatic anterior dislocation at 7 years associated with 5 mm subsidence of a non-collared stem. The initial squeaking and increased friction was due to the engineering of the liner / shell composite as implanted, not allowing adequate clearance for fluid film lubrication and contributed to by shell distortion during impaction. The revised bearings were “equatorial” rather than polar, and with lack of wear or creep this never fully resolved. Where the clearance was better, function was normal. The “slow” utilization was due to my ongoing concern with clearances not being correct. The revision of 4 Stemsys stems, tribology issues may have contributed, but non “MP-1” / Stemsys combinations outside this study have shown the same response, thought to be due to de-bonding of the hydroxyapatite coating. With correct engineering and clearances, a 3.6 mm thick MP-1 bearing, a surface Ra<0.5, steam sterilized, shows no appreciable wear, and with confidence, can be used as a high performance THR bearing

Hip resurfacing using metal-on-metal bearings has a number of purported advantages over traditional total hip replacement in the young, active patient. Males in particular can benefit from the bone preservation, stability, and higher activity levels seen with this procedure. As more is learned about the factors affecting long-term outcome of hip resurfacing, component position has emerged as one major predictor of success. Given a well-selected patient, and a well-designed device, acetabular positioning is perhaps the most important determinant of long-term survivorship in hip resurfacing. One feature of resurfacing socket design which has not been widely disseminated is the sub-hemispheric arc of the bearing surface. While the outer circumference of the socket represents a complete hemisphere, and radiographic evaluation may assume that the apparent socket angle is satisfactory, the actual bearing is less than a hemisphere, so that the true abduction of the bearing is considerably more vertical. This important fact leads to excessive bearing inclination, edge loading, and all that follows, including runaway wear, metallosis, ALVAL, and pseudotumors. Inadequate socket anteversion can expose the psoas tendon to abrasion and tendonitis. Too much acetabular anteversion, especially when combined with increased femoral neck anteversion, can result in an overall decrease in bearing contact area, and excessive wear. Femoral component positioning is critical in the prevention of femoral neck fractures, which are a chief cause of early failure. Varus placement increases the tensile stresses on the superior femoral neck. Excessive valgus threatens notching. Both increase femoral neck fractures. Sufficient malposition will ultimately result in edge loading. Edge wear is incompatible with fluid film lubrication, the key to longevity of these bearings

Introduction. Metal-on-polycarbonate urethane (MPU) is a cutting-edge new bearing technology for hip arthroplasty. The acetabular component consists of a 2.7mm-thick polycarbonate-urethane liner inserted into a specially manufactured uncemented titanium shell coated with hydroxyapatite [(HA) Fig. 1]. The liner is pliable and biomechanically mimics human cartilage. In vitro studies have shown minimal wear, fluid film lubrication, physiological load transmission and shock absorption capacity equal to the normal hip. This system includes prosthetic heads of a diameter 12mm less than the socket diameter. The aim of this study was to clinically assess patients treated with this novel technology in a retrospective single centre study. Methods. Twenty-seven patients with osteoarthritis treated with MPU bearing arthroplasty were included. Mean patient age was 67.9±10.35 years (44–84). Sixteen patients were female and 11 were male. Twenty-four of these had an uncemented HA-coated stem while 3 had a hip resurfacing metal femoral component. All patients were operated on by a single surgeon using a postero-lateral approach. Results. No patients were lost to follow-up. Mean follow-up time was 29 months (minimum 24 months). There were no major complications. At follow-up, the mean Harris hip score was 98 points (80–99). X-rays showed good bone-implant contact without any osteolysis or bone rarefaction. Discussion and conclusion. Our promising short-term results confirm the in vitro findings. Advantages of this new bearing technology include the possibility to use large diameter metal heads without exposing the patients to elevated levels of metal ions as is the case with metal-on-metal bearings, the minimal wear and the superior biomechanical characteristics

The ACCIS system comprises a bearing of a 5 micron surface ceramic upon a Chrome Cobalt Molybdenum (CrCoMo) substrate which allows for a homogeneous couple. The Titanium Niobium Nitride (TiNbN) microceramic applied by Plasma Vapour Deposition. In comparison with CrCoMo alloy, TiNbN gives a hard (2800 vs 489V), smooth (0.23 vs 0.55Rz), low friction (0.079–0.1 vs 0.11–0.56mu pin on disk test), wetable surface which when combined allows for the potential of gaining fluid film lubrication (lambda>3) on a smaller head diameter than an untreated surface. These properties are postulated to reduce wear and hence lower the release of Cr and Co ions in vivo. The surface microceramic also prevents exposure to release of Cr and Co by corrosion. The surface modified implants were first used in 2003 in large head arthroplasty and later in 2005 with resurfacing implants. Two series of patients implanted by a single surgeon were examined to elucidate the metal ion release of the ACCIS system. The first series retrospectively examined 52 consecutive Large Head Arthroplasty cases for [Cr], [Co] and [Mo] levels. A mean follow-up time of 7.5 yrs (77–101mths) with 9 patients being lost to revision and death by the time of the study. Median levels of [Cr] 1.6, [Co] 4.76 and [Mo] 2.5 µg/l were obtained. The second series prospectively examined the [Cr] and [Co] levels with the pre-operative values as controls in 125 resurfacing cases with the ACCIS microceramic. The second series gave no rising trend observed at up to 5 years ([Cr & Co] (range < 0.5–1.6 µg/l). It is postulated that the ACCIS surface microceramic reduces wear and also reduces the effective patch size for a given load thus allowing for a greater Patch to Edge Distance allowing a greater tolerance to cup positioning. A RCT is currently underway

Head sizes used in total hip arthroplasty (THA) has increased drastically from the original 22mm used by Charnley. This is due to two factors: the use of hard-on-hard materials for the bearing articulation and the increasing problem of dislocation. The tribological aspect. Hard-on-hard materials enable mixed or fluid film lubrication due to their good wettability. The development of a fluid film layer is encouraged by smaller surface pressures (larger area) and higher velocity at the articulating interface (larger radius), suggesting that larger diameters exhibit better lubrication and such less wear. This was effectivly proven in pre-clinical simulator studies and used as argument to increase the diameters of metal-on-metall and ceramic-on-ceramic bearings. Clinically the tribological advantage of larger diameters has not yet been shown. For hard-on-soft bearings the situation is different. Due to the bad wettability of Polyethylene (PE), the abrasive wear regime is dominant. This means that the longer wear path of a larger diameter will inevitably carry a larger amount of wear debris. Despite this relation, the heads used in combination with PE were also increased up to 40mm diameter, justified by the overall greatly reduced wear amount of the new generation(s) of cross-linked PE and favourable simulator results. First in-vivo studies have shown that larger heads carry larger amounts of wear particles. Whether this increase is relevant with respect to osteolysis is still unclear and will have to be shown in longer term studies. The biomechanical aspect. Larger heads require a larger “jumping” distance until they dislocate. Consequently the use of larger heads reduces dislocation rates, which was shown in multiple clinical studies. However, the reduction in dislocation rate achieved by increasing diameters varies greatly. Some centres achieve dislocation rates below 1% with 28mm heads, other centres require 36mm heads to achieve the same result. No study shows any further advantage with head diameters larger than 36mm. Despite their obvious biomechanical advantage with regard to stability, larger heads also have large disadvantages. Larger heads carry inevitably larger friction moments, requiring better anchoring of the components. In unfavourable conditions (start-up, break-down of lubrication film), friction moments of hard-on-hard bearings can get very high and reach or even exceed the losening torque of the head on the taper. Depending on the head impaction foce during assembly, the loosening torques amount to 8 to 17Nm. Movement at the head-taper connection possibly causes wear and increased corrosion at this interface. Larger head diameters also require thinner shells and/or liners, leading to problems with liner chipping or incomplete seating. Large head diameters have also lead to the use of sub-hemispherical cups with reduced covering surface, increasing the risk of fluid film break down due to edge loading if not well positioned. Finally, larger heads might give the surgeon a wrong feeling of security regarding a sub-optimal positioned cup. The question regarding “the optimal” head diameter is open for discussion and needs to consider the bearing material used. Head size should be limited to a reasonable compromise, which based on the information currently available, could be 36mm. Join the “36 and under” club