INTRODUCTION. Stable fixation of cementless tibial trays remains a challenge due bone density variability within the proximal tibia and the spectrum of loads imposed by different activities. This study presents a novel approach to measuring the interface motion of cementless tibial components during functional loading and tests whether interface motion of cementless tibial trays varies around the implant periphery. METHODS. We developed a method to measure relative displacement of a tibial tray relative to the underlying bone using 3D digital image correlation (DIC) and multi-camera stereo photogrammetry. A clinically successful design of cementless total knee prosthesis (Zimmer Inc, Warsaw, IN) was implanted in 6 fresh cadaveric knees. A black-on-white stochastic pattern was applied to the outer surface of the tibia and the cementless prosthesis. High resolution digital images were prepared of the interface region and divided into 25 × 25 pixel regions of interest (ROI). Stereo images of the same ROI were generated using two cameras angled at 60 degrees using image correlation techniques. All specimens were mounted in a custom-built functional activity simulator and loaded with the forces and moments recorded during three common functional activities (standing from a seated position, walking, and stair descent), as reported in the Orthoload database, scaled by 50% for application to cadaveric bone. Prior to functional testing, each implant-tibia construct was preconditioned with 500 cycles of flexion from 5–100 degrees under a vertical tibial load of 1050 N at a frequency of 0.2 Hz. During loading, image data was acquired simultaneously (±20 μs) from the entire circumference of the tibial interface forming 4 stereo images using 8 cameras spaced at 90 degree intervals (Allied Vision Technologies, Exton, PA) using custom image acquisition software (Mathworks, Natick, MA) (Figure 1). The multiple stereo images were registered using the surface topography of each specimen as measured by laser scanning (FARO Inc., Montreal) (Figure 2). During post-processing, the circumferential tray/tibia interface was divided into 10 zones for subsequent analysis (Figure 3). Interface displacements were measured on a point-to-point basis at approximately 700 sites on each specimen using commercial DIC software (Dantec Dynamics, Skovlunde, Denmark) (Figure 4). RESULTS. The average 3D displacement over 10 circumferential zones of the tray was 83.6±41.5 μm (range: 30.8 to 214.9 μm). The anatomic components of tray migration were 0.4±40.8 μm medially (range: 172 μm lateral to 112 μm medial) and 3.1± 40.6 μm posteriorly (range: 86 μm posteriorly to 61 μm anteriorly). The largest tray displacement was observed in the inferior direction with an average inferior displacement of 37.6±63.8 μm (range: 206 μm inferiorly to 81μm superiorly). The largest displacements were observed posteriorly, with the posteromedial aspect subsiding more the posterolateral aspect. DISCUSSION. The stability of tibial trays cannot be accurately assessed by measuring interface motion at a few fixed peripheral sites. If discrete displacement transducers are used for pre-clinical testing, a set of 4–6 transducers should be placed at sites that vary with the pattern of interface motion of each design and the combination of loads and moments applied during testing

Introduction. The release of metal debris and ions has raised concerns in joint arthroplasty. In THA metal debris and ions can be generated by wear of metal-on-metal bearing surfaces and corrosion at modular taper interfaces, currently understood to be mechanically assisted crevice corrosion (MACC) [1]. More recently, inflammatory-cell induced corrosion (ICIC) has been identified as a possible source of metal debris and/or ions [2]. Although MACC has been shown to occur at modular junctions in TKA, little is known about the prevalence of other sources. The purpose of this study was to determine the sources of metallic debris and ion release in long-term implanted (in vivo > 15y) TKA femoral components. Specific attention was paid to instances of ICIC as well as damage at the implant-bone interface. Methods. 1873 retrieved TKA components were collected from 2002–2013 as part of a multi-center, IRB-approved retrieval program. Of these, 52 CoCr femoral condyles were identified as long term TKA (Average: 17.9±2.8y). These components were predominantly revised for loosening, PE wear and instability. 40/52 of the components were primary surgeries. Components were examined using optical microscopy to confirm the presence of 5 damage mechanisms (polyethylene failure, MACC corrosion of modular tapers, corrosion damage between cement and backside, third-body wear, and ICIC). Third-body wear was evaluated using a semi-quantitative scoring method based on the percentage of damaged area. A score of 1 had minimal damage and a score of 4 corresponded to severe damage. Polyethylene components were scored using the Hood method and CoCr components were scored similarly to quantify metal wear. The total area damaged by ICIC was quantified using photogrammetry. Images were taken using a digital SLR with a calibrated ruler in the same focal plane. Using known pixel dimensions, the ICIC damaged area was calculated. Results. Surface damage indicative of corrosion and/or CoCr debris release was identified in 92% (n=48) of the components. Third-body wear was the most prevalent damage mechanism identified in 77% (n=40/52; Figure 1) of these components. ICIC was identified in 38% (n=20/52, figure 2) of the components. The polyethylene damage scores were predominantly a score of 4 out of a maximum score of 4 (89%). The corresponding femoral components had moderate to severe damage scores, with 39% with a score of 2, 37% scoring 3 and 22% scoring 4 out of a maximum score of 4. The total ICIC damaged area was an average of 0.11 ± 0.12 mm. 2. (Range: 0.01–0.46mm. 2. ). Discussion. In this study, we sought to identify mechanisms that could lead to the release of CoCr debris/ions in TKA. Five different mechanisms of potential metal release were observed. The most prevalent were third-body wear and ICIC damage. However the clinical implications remain unclear for several mechanisms because none of the devices were revised due to adverse local tissue reactions or biologic reactions to CoCr. Although we documented the prevalence of each damage mechanism, the quantity of metal removal was not investigated, warranting future studies