Aims. Porous metaphyseal cones can be used for fixation in revision total knee arthroplasty (rTKA) and complex TKAs. This metaphyseal fixation has led to some surgeons using shorter cemented stems instead of diaphyseal engaging cementless stems with a potential benefit of ease of obtaining proper alignment without being beholden to the diaphysis. The purpose of this study was to evaluate short term clinical and radiographic outcomes of a series of TKA cases performed using 3D-printed metaphyseal cones. Methods. A retrospective review of 86 rTKAs and nine complex primary TKAs, with an average age of 63.2 years (SD 8.2) and BMI of 34.0 kg/m. 2. (SD 8.7), in which metaphyseal cones were used for both femoral and tibial fixation were compared for their knee alignment based on the type of stem used. Overall, 22 knees had cementless stems on both sides, 52 had cemented stems on both sides, and 15 had mixed stems. Postoperative long-standing radiographs were evaluated for coronal and sagittal plane alignment. Adjusted logistic regression models were run to assess malalignment hip-knee-ankle (HKA) alignment beyond ± 3° and sagittal alignment of the tibial and femoral components ± 3° by stem type. Results. No patients had a revision of a cone due to aseptic loosening; however, two had revision surgery due to infection. In all, 26 (27%) patients had HKA malalignment; nine (9.5%) patients had sagittal plane malalignment, five (5.6%) of the tibia, and four (10.8%) of the femur. After adjusting for age, sex, and BMI, there was a significantly increased risk for malalignment when a cone was used and both the femur and tibia had cementless compared to cemented stems (odds ratio 3.19, 95% confidence interval 1.01 to 10.05). Conclusion. Porous 3D-printed cones provide excellent metaphyseal fixation. However, these central cones make the use of offset couplers difficult and may generate malalignment with cementless stems. We found 3.19-times higher odds of malalignment in our TKAs performed with metaphyseal cones and both femoral and tibial cementless stems. Cite this article: Bone Joint J 2021;103-B(6 Supple A):150–157

Aims. Metaphyseal tritanium cones can be used to manage the tibial bone loss commonly encountered at revision total knee arthroplasty (rTKA). Tibial stems provide additional fixation and are generally used in combination with cones. The aim of this study was to examine the role of the stems in the overall stability of tibial implants when metaphyseal cones are used for rTKA. Methods. This computational study investigates whether stems are required to augment metaphyseal cones at rTKA. Three cemented stem scenarios (no stem, 50 mm stem, and 100 mm stem) were investigated with 10 mm-deep uncontained posterior and medial tibial defects using four loading scenarios designed to mimic activities of daily living. Results. Small micromotions (mean < 12 µm) were found to occur at the bone-implant interface for all loading cases with or without a stem. Stem inclusion was associated with lower micromotion, however these reductions were too small to have any clinical significance. Peak interface micromotion, even when the cone is used without a stem, was too small to effect osseointegration. The maximum difference occurred with stair descent loading. Stress concentrations in the bone occurred around the inferior aspect of each implant, with the largest occurring at the end of the long stem; these may lead to end-of-stem pain. Stem use is also found to result in stress shielding in the bone along the stem. Conclusion. When a metaphyseal cone is used at rTKA to manage uncontained posterior or medial defects of up to 10 mm depth, stem use may not be necessary. Cite this article:Bone Joint Res. 2020;9(4):162–172

Aims. Metaphyseal cones with cemented stems are frequently used in revision total knee arthroplasty (TKA). However, if the diaphysis has been previously violated, the resultant sclerotic canal can impair cemented stem fixation, which is vital for bone ingrowth into the cone, and long-term fixation. We report the outcomes of our solution to this problem, in which impaction grafting and a cemented stem in the diaphysis is combined with an uncemented metaphyseal cone, for revision TKA in patients with severely compromised bone. Methods. A metaphyseal cone was combined with diaphyseal impaction grafting and cemented stems for 35 revision TKAs. There were two patients with follow-up of less than two years who were excluded, leaving 33 procedures in 32 patients in the study. The mean age of the patients at the time of revision TKA was 67 years (32 to 87); 20 (60%) were male. Patients had undergone a mean of four (1 to 13) previous knee arthroplasty procedures. The indications for revision were aseptic loosening (80%) and two-stage reimplantation for prosthetic joint infection (PJI; 20%). The mean follow-up was four years (2 to 11). Results. Survival free from revision of the cone/impaction grafting construct due to aseptic loosening was 100% at five years. Survival free from any revision of the construct and free from any reoperation were 92% and 73% at five years, respectively. A total of six patients (six TKAs, 17%) required a further revision, four for infection or wound issues, and two for periprosthetic fracture. Radiologically, one unrevised TKA had evidence of loosening which was asymptomatic. In all unrevised TKAs the impacted diaphyseal bone graft appeared to be incorporated radiologically. Conclusion. When presented with a sclerotic diaphysis and substantial metaphyseal bone loss, this technique combining diaphyseal impaction grafting with a metaphyseal cone provided near universal success in relation to implant fixation. Moreover, radiographs revealed incorporation of the bone graft and biological fixation of the cone. While long-term follow-up will be important, this technique provides an excellent option for the management of complex revision TKAs. Cite this article: Bone Joint J 2020;102-B(6 Supple A):116–122

Aims. Metaphyseal fixation during revision total knee arthroplasty (TKA) is important, but potentially difficult when using historical designs of cone. Material and manufacturing innovations have improved the size and shape of the cones which are available, and simplified the required bone preparation. In a large series, we assessed the implant survivorship, radiological results, and clinical outcomes of new porous 3D-printed titanium metaphyseal cones featuring a reamer-based system. Methods. We reviewed 142 revision TKAs in 139 patients using 202 cones (134 tibial, 68 femoral) which were undertaken between 2015 and 2016. A total of 60 involved tibial and femoral cones. Most cones (149 of 202; 74%) were used for Type 2B or 3 bone loss. The mean age of the patients was 66 years (44 to 88), and 76 (55 %) were female. The mean body mass index (BMI) was 34 kg/m. 2. (18 to 60). The patients had a mean of 2.4 (1 to 8) previous operations on the knee, and 68 (48%) had a history of prosthetic infection. The mean follow-up was 2.4 years (2 to 3.6). Results. Survivorship free of cone revision for aseptic loosening was 100% and survivorship free of any cone revision was 98%. Survivorships free of any revision and any reoperation were 90% and 83%, respectively. Five cones were revised: three for infection, one for periprosthetic fracture, and one for aseptic tibial loosening. Radiologically, three unrevised femoral cones appeared loose in the presence of hinged implants, while the remaining cones appeared stable. All cases of cone loosening occurred in patients with Type 2B or 3 defects. The mean Knee Society score (KSS) improved significantly from 50 (0 to 94) preoperatively to 87 (72 to 94) (p < 0.001). Three intraoperative fractures with cone impaction (two femoral, one tibial) healed uneventfully. Conclusion. Novel 3D-printed titanium cones, with a reamer-based system, yielded excellent early survivorship and few complications in patients with severe bone loss undergoing difficult revision TKA. The diversity of cone options, relative ease of preparation, and outcomes rivalling those of previous designs of cone support their continued use. Cite this article: Bone Joint J 2020;102-B(6 Supple A):107–115

Metaphyseal bone loss is common with revision total knee replacement (RTKR). Using the Anderson Orthopaedic Research Institute (AORI) classification, type 2-B and type 3 defects usually require large metal blocks, bulk structural allograft or highly porous metal cones. Tibial and femoral trabecular metal metaphyseal cones are a unique solution for large bone defects. These cones substitute for bone loss, improve metaphyseal fixation, help correct malalignment, restore the joint line and may permit use of a shorter stem. The technique for insertion involves sculpturing of the remaining bone with a high speed burr and rasp, followed by press-fit of the cone into the metaphysis. The fixation and osteoconductive properties of the porous cone outer surface allow ingrowth and encourage long-term biological fixation. The revision knee component is then cemented into the porous cone inner surface, which provides superior fixation compared with cementing into native but deficient metaphyseal bone. The advantages of the cone compared with allograft include: technical ease, biological fixation, no resorption, and possibly a lower risk of infection. The disadvantages include: difficult extraction and relatively short-term follow-up. Several studies using cones report promising short-term results for the reconstruction of large bone defects in RTKR.

Cite this article: Bone Joint J 2014;96-B(11 Suppl A):118–21.

The February 2024 Knee Roundup. 360. looks at: Do patients with hypoallergenic total knee arthroplasty implants for metal allergy do worse? An analysis of healthcare utilizations and patient-reported outcome measures; Defining a successful total knee arthroplasty; Incidence, microbiological studies, and factors associated with periprosthetic joint infection after total knee arthroplasty; A modified Delphi consensus statement on patellar instability; Cause for concern? Significant cement coverage in retrieved metaphyseal cones after revision total knee arthroplasty; Prevalence of post-traumatic osteoarthritis after anterior cruciate ligament injury remains high despite advances in surgical techniques; Cost-effectiveness of arthroscopic partial meniscectomy versus physical therapy for traumatic meniscal tears in patients aged under 45 years

Introduction. Porous metaphyseal cones are increasingly used for fixation in revision total knee arthroplasty (RTKA). Both cemented shorter length stems and longer diaphyseal engaging stems are currently utilized with metaphyseal cones with no clear evidence of superiority. The purpose of this study was to evaluate our experience with 3D printed titanium metaphyseal cones with both short cemented and longer cementless stems from a clinical and radiographic perspective. Methods. In total 136 3D printed titanium metaphyseal cones were implanted. The mean patient age was 63 and 48% were female. The mean BMI was 33 and the mean ASA class was 2.5. There were 42 femoral cones in which 28 cemented and 14 cementless stems were utilized. There were 94 tibial cones in which 67 cemented and 27 cementless stems were utilized. The choice for stem fixation was surgeon dependent and in general cones were utilized for AORI type 2 and 3 bone defects on the femur and tibia. The most common fixation scenario was short cemented stems on both the femur and tibia followed by cemented stem fixation on the tibia and cementless fixation on the femur. Clinical data such as revision, complication, and PRO was collected at last follow-up (minimum follow-up 1 year). Radiographic analysis included cone bony ingrowth and coronal and sagittal alignment on long-standing radiographs. Descriptive statistics were used to compare demographics between patients who had malalignment (HKA beyond +/− 3 degrees and flexion/extension beyond +/− 3 degrees). Adjusted logistic regression models were run to assess malalignment risk by stem type. Results. Patient reported outcomes demonstrated modest improvements with Pre-op KOOS improving from 44 pre-op to 59 post -op and PF-CAT improving from 33 to 37 post-op. PROMIS pain scores decreased significantly from 54 to 44 post-op. 36% of patients had malalignment in either the coronal or sagittal plane. Patients with malalignment were more likely to be female (66.7% vs 40.4%, p-value=0.02). After adjusting for age, sex and BMI, there was a significantly increased risk for coronal plane malalignment when both the femur and tibia had cementless compared to cemented stems (odds ratio=5.54, 95%CI=1.15, 26.80). There was no significantly increased risk when comparing patients with mixed stems to patients with cemented stems. Sagittal plane malalignment was more common with short cemented stems although both coronal plane and sagittal plane malalignment with either stem type was not associated with inferior clinical outcome. Overall cone survivorship was excellent with only two cones removed for infection. Conclusion. Metaphyseal titanium cones provide reliable fixation in revision TKA. However, PROs in this complex patient population show only modest improvement consistent with other variables such as co-morbidities and poor baseline physical function. Small cone inner diameter may adversely influence cementless stem position leading to coronal plane malalignment. Short cemented stems are subject to greater sagittal plane malalignment with no apparent influence on clinical outcome

Introduction. Metaphyseal cones with cemented stems are frequently used in revision total knee arthroplasties (TKAs). However, if the diaphysis has been previously violated (as in revision of a failed stemmed implant), the resultant sclerotic canal can impair cemented stem fixation, which is vital for cone ingrowth and long-term fixation. We report the outcomes of our novel solution to this problem, in which impaction grafting and a cemented stem in the diaphysis was combined with an uncemented metaphyseal cone for revision TKAs with severely compromised bone. Methods. A metaphyseal cone was combined with diaphyseal impaction grafting and cemented stems in a novel fashion for 35 revision TKAs. Mean age at revision TKA was 70 years, with 63% being male. Patients had a mean of 4 prior knee arthroplasty procedures. Indications for the revision with this construct were aseptic loosening (80%) and two-stage re-implantation for periprosthetic infection (PJI; 20%). Mean follow-up was 3 years. Results. Survivorship free from revision of the cone/impaction grafting construct due to aseptic loosening was 100% at 5 years. Survivorships free from any revision of the cone/impaction grafting construct and free from any reoperation were 92% and 73% at 5 years, respectively. Six knees (17%) required a reoperation (4 for infection/wound issues and 2 for periprosthetic fractures). Radiographically, 97% of cones were ingrown (1 loose cone in setting of PJI). In all but one case, impacted diaphyseal bone graft appeared to have incorporated radiographically. Conclusions. When presented with a sclerotic diaphysis and substantial metaphyseal bone loss, this innovative technique combining diaphyseal impaction grafting with a metaphyseal cone provided near universal success in regards to implant fixation. Moreover, radiographs revealed incorporation of the bone graft, and ingrowth of the cones. While long-term follow-up is required, this novel technique provides an excellent option in the most difficult of revision TKAs. For figures, tables, or references, please contact authors directly

Massive bone loss on both the femur and tibia during revision total knee arthroplasty (TKA) remains a challenging problem. Multiple solutions have been proposed for small osseous defects, including morselised cancellous bone grafting, small-fragment structural allograft, thicker polyethylene inserts, and the use of modular augments attached to revision prosthetic designs. Large osseous defects can be treated with structural allografts, impaction bone-grafting with or without mesh augmentation, custom prosthetic components, and specialised hinged knee components. The metaphyseal area of the distal femur and proximal tibia is a particularly attractive option during revision TKA given that it is usually undamaged and well-vascularised. While multiple reconstructive options have been recommended, porous tantalum metaphyseal cones have the advantage of improved biologic fixation because of their high porosity (75–80%), interconnected pore space, and low modulus of elasticity (3 MPa) similar to that of cancellous bone. Such features allow tantalum cones to fill bone defects while tolerating physiological loads. Indications for porous tantalum metaphyseal cones include patients with Anderson Orthopaedic Research Institute Type 2B or greater defects. The surgical technique is simpler than structural allograft reconstructions with decreased preparation time, resulting in a possible decrease in infection rates. The modularity of porous tantalum metaphyseal cones also allows the surgeon to choose a size and position that best fits the individual defect encountered. Moreover, tantalum cones can be used with several revision systems. Short-term clinical follow up indicates that porous tantalum metaphyseal cones effectively provide structural support with the potential for long-term biologic fixation and durable reconstructions

Introduction. Modularity in femoral stem designs allow surgeons to independently control leg length, offset, and femoral version in revision or complex primary THA cases. Initial enthusiasm in these modular stems has been tempered by recognition of modular junction failures. This study evaluates mean 5-year clinical results and survival rates of a 3-part titanium alloy modular femoral implant with unique taper geometries and a metaphyseal plasma spray surface. The current results are presented after pre-market independent fatigue testing performed by Orthopaedic Laboratory (Greenwald) and previously published early clinical results in 2006. Low plasticity burnishing (LPB) was added in 2005 to further strengthen the neck metaphyseal modular junction. The modular stem component is a polished cylindrical splined clothespin design. Our hypothesis is that these unique modular junctions succeed in offering the advantages of modularity without failure at this midterm follow-up period. Methods. Between May 2010 and July 2016, 32 total hip arthroplasties were performed using a 3-part femoral stem with neck-metaphyseal-stem modular junctions. Surgeries were either the final stage of a two-stage revision for infection, revision THR for loosening, or a revision of a previous non-prosthetic replacement procedure. Patients were entered into an IRB-approved registry and followed with x-rays, HHS, Oxford scores, and patient satisfaction scores. Patients who failed to return for routine follow-up were contacted by phone or email. Two patients had died with their implants intact. Six patients could not be reached for an updated follow-up. One stem was revised for loosening at 33 months due to failed osseointegration in a patient with chronic renal failure. This removed stem was submitted for taper exam and sectioning. Results. There were 23 patients for evaluation at a mean 61 months (range 21–98). Mean patient age at implantation was 56 (range 25–88), BMI was 27 (range 20–40). There were no modular junction failures. Modular junctions examined in the retrieved implant did not demonstrate any abnormalities other than normal wear properties. HHS and OHS scores both improved between pre-op and final follow-up, 23 to 85 and 17 to 43, respectively. Average patient satisfaction score at final follow-up was 9.8 out of 10 (min 8, max 10). Radiographic examination showed stem subsidence > 2mm and radiolucencies around the metaphyseal cone in 1 patient, the same patient who required implant removal. Radiolucencies were seen along the polished stem tip in 43% of cases, spot welding at the distal metaphyseal cone in 67% of cases, and mild proximal-medial stress shielding in 33% of cases. Conclusion. This unique 3-part modular stem with metaphyseal fixation shows good functional and radiographic results at 5-year follow-up. There were no junctional failures. One stem was removed due to failure to osseointegrate and showed no worrisome taper abnormalities. Spot welding is common around the plasma spray metaphyseal cone. Implant removal, if necessary, only requires disruption of the metaphyseal fixation. Further follow-up will be important to confirm our confidence in this unique stem design

Aims. Varus-valgus constrained (VVC) implants are often used during revision total knee arthroplasty (TKA) to gain coronal plane stability. However, the increased mechanical torque applied to the bone-cement interface theoretically increases the risk of aseptic loosening. We assessed mid-term survivorship, complications, and clinical outcomes of a fixed-bearing VVC device in revision TKAs. Methods. A total of 416 consecutive revision TKAs (398 patients) were performed at our institution using a single fixed-bearing VVC TKA from 2007 to 2015. Mean age was 64 years (33 to 88) with 50% male (199). Index revision TKA diagnoses were: instability (n = 122, 29%), aseptic loosening (n = 105, 25%), and prosthetic joint infection (PJI) (n = 97, 23%). All devices were cemented on the epiphyseal surfaces. Femoral stems were used in 97% (n = 402) of cases, tibial stems in 95% (n = 394) of cases; all were cemented. In total, 93% (n = 389) of cases required a stemmed femoral and tibial component. Femoral cones were used in 29%, and tibial cones in 40%. Survivorship was assessed via competing risk analysis; clinical outcomes were determined using Knee Society Scores (KSSs) and range of movement (ROM). Mean follow-up was four years (2 to 10). Results. The five-year cumulative incidence of subsequent revision for aseptic loosening and instability were 2% (95% confidence interval (CI) 0.2 to 3, number at risk = 154) and 4% (95% CI 2 to 6, number at risk = 153), respectively. The five-year cumulative incidence of any subsequent revision was 14% (95% CI 10 to 18, number at risk = 150). Reasons for subsequent revision included PJI (n = 23, of whom 12 had previous PJI), instability (n = 13), and aseptic loosening (n = 11). The use of this implant without stems was found to be a significant risk factor for subsequent revision (hazard ratio (HR) 7.58 (95% CI 3.98 to 16.03); p = 0.007). KSS improved from 46 preoperatively to 81 at latest follow-up (p < 0.001). ROM improved from 96° prerevision to 108° at latest follow-up (p = 0.016). Conclusion. The cumulative incidence of subsequent revision for aseptic loosening and instability was very low at five years with this fixed-bearing VVC implant in revision TKAs. Routine use of cemented and stemmed components with targeted use of metaphyseal cones likely contributed to this low rate of aseptic loosening. Cite this article: Bone Joint J 2020;102-B(4):458–462

Aim. Femoral or tibial massive bone defects (AORI F2B-F3 / T2B-T3) are common in septic total knee replacement. Different surgical techniques are described in literature. In our study we show clinical and radiological results associated with the use of tantalum metaphyseal cones in the management of cavitary bone defects in two-stage complex knee revision. Method. Since 2010 we have implanted 70 tantalum metaphyseal cones associated with constrained or semiconstrained knee prostheses in 47 patients. The indication for revision was periprosthetic knee infection (43 cases, 91.5%) or septic knee arthritis (4 patients, 8.5%) with massive bone defect. All cases underwent a two-stage procedure. Patients were screened for main demographic and surgical data. Clinical and radiological analysis was performed in the preoperative and at 3,6 months, 1 years and each year thereafter in the postoperative. The mean follow-up was 31.1 months ± 18.8. No dropout was observed. Results. Objective and subjective functional scores (KSS, OKS) showed a statistically significant improvement from the preoperative to last follow-up (p <0.001). All cones but one (98.6%) showed radiological osteointegration. We did not find any cone-related intraoperative or postoperative mechanical complication with a 100% survival rate when we consider aseptic loosening as cause of revision. Six non progressive radiolucencies were observed. Two septic failures (4.3%) with implant and cone removal were reported. Conclusions. The ideal treatment for cavitary bone defects in two-stage TKA septic revision is still unclear. The use of metaphyseal tantalum cones showed excellent clinical and radiographic results with a low rate of related complications. The main finding of our study is the cone-related infection rate (2.9%) in this particular series of patients. This data is comparable or better than other previous report about this topic with unhomogeneous cohort of patients

The amount of bone loss due to implant failure, loosening, or osteolysis can vary greatly and can have a major impact on reconstructive options during revision total knee arthroplasty (TKA). Massive bone loss can threaten ligamentous attachments in the vicinity of the knee and may require use of components with additional constraint to compensate for associated ligamentous instability. Classification of bone defects can be helpful in predicting the complexity of the reconstruction required and in facilitating preoperative planning and implant selection. One very helpful classification of bone loss associated with TKA is the Anderson Orthopaedic Research Institute (AORI) Bone Defect Classification System as it provides the means to compare the location and extent of femoral and tibial bone loss encountered during revision surgery. In general, the higher grade defects (Type IIb or III) on both the femoral and tibial sides are more likely to require stemmed components, and may require the use of either structural graft or large augments to restore support for currently available modular revision components. Custom prostheses were previously utilised for massive defects of this sort, but more recently have been supplanted by revision TKA component systems with or without special metal augments or structural allograft. Options for bone defect management are: 1) Fill with cement; 2) Fill with cement supplemented by screws or K-wires; 3) Morselised bone grafting (for smaller, especially contained cavitary defects); 4) Small segment structural bone graft; 5) Impaction grafting; 6) Porous metal cones or sleeves 7) Massive structural allograft-prosthetic composites; 8) Custom implants. Of these, use of uncemented highly porous metal metaphyseal cones in combination with an initial cemented or partially cemented implant has been shown to provide versatile and highly durable results for a range of bone defects including those previously requiring structural bone graft. The hybrid fixation combination of both cement and cementless fixation of an individual tibial or femoral component has emerged as a frequent and often preferred technique. Initial secure and motionless interfaces are provided by the cemented portions of the construct, while subsequent bone ingrowth to the cementless porous metal portions is the key to long term stable fixation. As bone grows into the porous portions there is off loading and protection of the cemented interfaces from mechanical stresses. While maximizing support on intact host bone has been a longstanding fundamental principle of revision arthroplasty, this is facilitated by the use of metaphyseal cones or sleeves in combination with initial fixation into the adjacent diaphysis. Preoperative planning is facilitated by good quality radiographs, supplemented on occasion by additional imaging such as CT. Fluoroscopically controlled x-ray views may assist in diagnosing the loose implant by better revealing the interface between the implant and bone and can facilitate accurate delineation of the extent of bone deficiency present. Part of the preoperative plan is to ensure adequate range and variety of implant choices and bone graft resources for the planned reconstruction allowing for the potential for unexpected intraoperative findings such as occult fracture through deficient periprosthetic bone. While massive bone loss may compromise ligamentous attachment to bone, in the majority of reconstructions, the degree of revision implant constraint needed for proper balancing and restoration of stability is independent of the bone defect. Thus, some knees with minimal bone deficiency may require increased constraint due to the status of the soft tissues while others involving very large bone defects, especially of the cavitary sort, may be well managed with minimal constraint

Introduction. Metaphyseal fixation during revision total knee arthroplasties (TKAs) is important, but potentially challenging with historical cone designs. Material and manufacturing innovations have improved the size and shape of cones available, and simplified requisite bone preparation. In a very large series, we assessed implant survivorship, radiographic results, and clinical outcomes of new porous 3-D printed titanium metaphyseal cones featuring a reamer-based system. Methods. We reviewed 142 revision TKAs using 202 cones (134 tibial and 68 femoral) from 2015 to 2016. Sixty cases involved tibial and femoral cones. Most cones (149 of 202; 74%) were used for Type 2B or 3 bone loss. Mean age was 66 years, with 54 % females. Mean BMI was 34 kg/m. 2. Patients had a mean of 2.4 prior surgeries and 48% had a history of periprosthetic infection. Mean follow-up was 2 years. Results. At 2 years, survivorship free of cone revision for aseptic loosening was 100% and free of cone revision for any reason was 98%. Survivorships free of any component revision and any reoperation were 90% and 83%. Five cones had been revised at latest follow-up: 3 for infection, 1 for periprosthetic fracture, and 1 for aseptic tibial loosening. Radiographically, three unrevised femoral cones appeared loose in the presence of hinged implants, while the remainder of cones appeared stable. All cases of cone loosening occurred in Type 2B or 3 defects. Mean Knee Society scores improved from 50 preoperatively to 87 at latest follow-up (p<0.001). Three intraoperative fractures with cone impaction (two femoral, one tibial) all healed uneventfully. Conclusion. Novel 3-D printed titanium cones, with an efficient mill system, yielded excellent early survivorship and few complications in difficult revision TKAs with severe bone loss. The diversity of cone options, relative ease of preparation, and outcomes rivaling prior cone designs support the continued use of these modern cones. For figures, tables, or references, please contact authors directly

The management of bone loss in revision total knee replacement (TKA) remains a challenge. To accomplish the goals of revision TKA, the surgeon needs to choose the appropriate implant design to “fix the problem,” achieve proper component placement and alignment, and obtain robust short- and long-term fixation. Proper identification and classification of the extent of bone loss and deformity will aid in preoperative planning. Extensive bone loss may be due to progressive osteolysis (a mechanism of failure), or as a result of intraoperative component removal. The Anderson Orthopaedic Research Institute (AORI) is a useful classification system that individually describes femoral and tibial defects by the appearance, severity, and location of bone defects. This system provides a guideline to treatment and enables preoperative planning on radiographs. In Type 1 defects, femoral and tibial defects are characterised by minor contained deficiencies at the bone-implant interface. Metaphyseal bone is intact and the integrity of the joint line is not compromised. In this scenario, the best reconstruction option is to increase the thickness of bone resection and to fill the defect with cancellous bone graft or cement. Type 2 defects are characterised by deficient metaphyseal bone involving one or more femoral condyle(s) or tibial plateau(s). The peripheral rim of cortical bone may be intact or partially compromised, and the joint line is abnormal. Reconstruction options for a Type 2A defect include impaction bone grafting, cement, or more commonly, prosthetic augmentation (e.g. sleeves, augments or wedges). In Type 2B defects, metaphyseal bone of both femoral condyles or both tibial plateaus is deficient. The peripheral rim of cortical bone may be intact or partially compromised, and the joint line is abnormal. Options for a Type 2B defect include impaction grafting, bulk structural allograft, prosthetic augmentation, metaphyseal sleeves (in some cases), or metaphyseal cones. Finally, in the presence of a Type 3 deficiency, both metaphyseal and cortical bone is deficient and there is partial or complete disruption of the collateral ligament attachments. In this case, the most commonly used reconstruction options include hinged implants or megaprostheses with or without bulk structural allograft, prosthetic augmentation, and/or metaphyseal/diaphyseal sleeves or cones. Today, we are fortunate to have a wide variety of options available to aid in reconstruction of a revision TKA with massive bone loss. Historically, use of cement, bone grafting, or use of a tumor-type or hinged implant were considered the main options for reconstruction. The development and adoption of highly porous sleeves and cones has given the surgeon a new and potentially more durable option for reconstruction of previously difficult to treat defects. Using radiographs and computed tomography, surgeons are able to preoperatively classify bone loss and anticipate a reconstruction plan based upon the classification; however, it is always important to have several back-up options on hand during revision surgery in the event bone loss is worse than expected

Stems provide short- and long-term stability to the femoral and tibial components. Poorer epiphyseal and metaphyseal bone quality will require sharing or offloading the femoral and tibial component interfaces with a stem. One needs to use stem technique most appropriate for each individual case because of variable anatomy and bone loss situations. The conflict with trying to obtain stability via the stem is that most stems are cylindrical but femoral and tibial metaphyseal/diaphyseal areas are conical in shape. Viable stem options include fully cemented short and long stems, uncemented long stems, offset uncemented stems, and a hybrid application of a cemented proximal end of longer uncemented diaphyseal engaging stems. Stems are not without their risk. The more the load is transferred to the cortex, the greater the risk of proximal interface stress shielding. A long uncemented stem has similar stress shielding as a short cemented stem. Long diaphyseal engaging stems that are cemented or uncemented have the potential to have end of stem pain, especially if more diaphyseal reaming is done to obtain greater cortical contact. A conical shaped long stem can provide more stability than a long cylindrical stem and avoid diaphyseal reaming. Use of long stems may create difficulty in placement of the tibial and femoral components in an optimal position. If the femoral or tibial components do not allow an offset stem insertion, using a long offset stem or short cemented stem is preferred. The amount of metaphyseal bone loss will drive the choice of stem used. Short cemented stems will not have good stability in poor metaphyseal bone without getting the cement out to the cortex. Long cemented stems provide satisfactory survivorship, however, most surgeons avoid cementing long stems due to the difficulty of removal, if a subsequent revision is required. If the metaphyseal bone is excellent, use of a short cemented stem or long uncemented stem can be expected to have good results. Long fully uncemented stems must have independent stability to be effective, or should be proximally cemented as a hybrid technique. Cases with AOI type IIb and III tibial and femoral defects are best managed with use of metaphyseal cones with short cemented stems or long hybrid straight or offset stems. Some studies also suggest that if the cone is very stable, no stem may be required. My preference is to use a short cemented stem or hybrid conical stem in patients with good metaphyseal bone. If significant metaphyseal bone loss is present, I will use a porous cone with either a short cemented stem, hybrid cylindrical or offset stem depending on the primary stability of the cone and whether the femoral or tibial component can be placed in an optimal position in patients with good metaphyseal bone

Metaphyseal bone loss, due to loosening, osteolysis or infection, is common with revision total knee arthroplasty (TKA). Small defects can be treated with screws and cement, bone graft, and non-porous metal wedges or blocks. Large defects can be treated with bulk structural allograft, impaction grafting, or highly porous metal cones. The AORI classification of bone loss in revision TKA is very helpful with pre-operative planning. Type 1 defects do not require augments or graft—use revision components with stems. Type 2A defects should be treated with non-porous metal wedges or blocks. Type 2B and 3 defects require a bulk structural allograft or porous metal cone. Highly-porous metal metaphyseal cones are a unique solution for large bone defects. Both femoral (full or partial) and tibial (full, stepped, or cone+plate) cones are available. These cones substitute for bone loss, improve metaphyseal fixation, help correct malalignment, restore joint line, and permit use of a short cemented stem. The technique for these cones involve preparing the remaining bone with a high speed burr and rasp, followed by press-fit of the cone into the remaining metaphysis. The interface is sealed with bone graft and putty. The fixation and osteoconductive properties of the outer surface allow ingrowth and biologic fixation. The revision knee component is then implanted, with antibiotic-cement, into the porous cone inner surface, which provides superior fixation compared to cementing into deficient metaphyseal bone. There are several manufacturers that provide porous cones for knee revision, but the tantalum-“trabecular metal” cones have the largest and longest clinical follow-up. The advantages of the trabecular metal cone compared to allograft include: technically easier; biologic fixation; no resorption; and lower risk of infection. The disadvantages include: difficult extraction and intermediate-term follow-up. The author has reported the results of 33 trabecular metal cones (9 femoral, 24 tibial) implanted in 27 revision cases at 2–5.7 years follow-up. One knee (2 cones) was removed for infection. All but one cone showed osseointegration. Multiple other studies have confirmed these results. Trabecular metal cones are now the author's preferred method for the reconstruction of large bone defects in revision TKA

Introduction. Extraction of implants due to periprosthetic infection (PJI) following complex revision total knee arthroplasty (rTKA) with extensive hardware can be a daunting undertaking for surgeon and patient alike. We question whether irrigation and debridement (I&D) has a role in this difficult situation with respect to infection control, reoperation, and function. Methods. rTKAs for PJI from 2005–2016 were reviewed. Extensive hardware was defined as: metaphyseal cone/sleeve fixation, distal femoral replacement, periprosthetic fracture hardware, or stems >75mm. Cases were categorized by treatment (I&D or 2-stage exchange). Results. 87 patients were identified with extensive hardware and PJI − 63 I&Ds and 42 2-stages. Follow-up was 3.7 years. Success defined as no re-operation for infection was similar − 38/63 (60.3%) I&D vs 28/42 (66.7%) 2-stage (p=0.54). 26/42 (61.9%) 2-stages required static spacers for post-extraction bone loss or wound problems. Only 14/42 (33%) 2-stages were successfully replanted without re-infection. 11/42 (26.1%) 2-stages had retained spacers while 7/42 (16.7%) 2-stages were eventually fused. In contrast, 38/63 (60.3%) I&Ds maintained original implants without further surgery. 8/63 (12.7%) required repeat I&D; 9/63 (14.3%) underwent eventual 2-stage. Chronic antibiotic suppression was utilized in 53/63 (84.1%) I&Ds and 17/42 (40.5%) 2-stages (p<0.001). Amputation rates were similar − 9/63 (14.3%) I&D vs 7/42 (16.7%) 2-stage (p=0.79). Ambulatory rates were similar − 46/63 (73.0%) I&D vs 24/42 (57.1%) 2-stage (p=0.09). More patients who underwent I&D had a functional TKA at final follow-up (53/63 (84.1%) I&D vs 20/42 (47.6%) 2-stage; p<0.001). Mortality was high − 22/59 (37.3%) I&D vs 13/37 (35.1%) 2-stage (p=1.00). Conclusion. In the setting of PJI following rTKA with extensive hardware, morbidity and mortality is high. I&D with chronic suppression appears as effective as 2-stage procedures in preventing reoperation for infection and maintaining ambulatory status while avoiding the morbidity of 2-stage exchange

Metaphyseal bone loss, due to loosening, osteolysis or infection, is common with revision total knee arthroplasty (TKA). Small defects can be treated with screws and cement, bone graft, and non-porous metal wedges or blocks. Large defects can be treated with bulk structural allograft, impaction grafting, or highly porous metal cones. The AORI classification of bone loss in revision TKA is very helpful with preoperative planning. Type 1 defects do not require augments or graft—use revision components with stems. Type 2A defects should be treated with non-porous metal wedges or blocks. Type 2B and 3 defects require a bulk structural allograft or porous metal cone. Trabecular metal (TM) metaphyseal cones are a unique solution for large bone defects. Both femoral (full or partial) and tibial (full, stepped, or cone+plate) TM cones are available. These cones substitute for bone loss, improve metaphyseal fixation, help correct malalignment, restore joint line, and permit use of a short cemented stem. The technique for these cones involve preparing the remaining bone with a high speed burr and rasp, followed by press-fit of the cone into the remaining metaphysis. The interface is sealed with bone graft and putty. The fixation and osteoconductive properties of the outer surface allow ingrowth and biologic fixation. The revision knee component is then cemented into the porous cone inner surface, which provides superior fixation compared to cementing into deficient metaphyseal bone. The advantages of the TM cone compared to allograft include: technically easier; biologic fixation; no resorption; and lower risk of infection. The disadvantages include: difficult extraction and intermediate-term follow-up. The author has reported the results of 33 TM cones (9 femoral, 24 tibial) implanted in 27 revision cases at 2–5.7 years follow-up. One knee (2 cones) was removed for infection. All but one cone showed osseointegration. TM cones are now the preferred method for the reconstruction of large bone defects in revision TKA

Restoration of bone loss is a major challenge of revision TKA surgery. It is critical to achieve of a stable construct to support implants and achieve successful results. Major bone defects of the femoral and/or tibia (AORI type IIB/III) have been reconstructed using impaction grafting, structural allografts or tumor prostheses. The major concerns with structural allograft are graft resorption, mechanical failure, tissue availability, disease transmission, considerable surgical skill required and prolonged operative time. Porous tantalum metaphyseal cones, are becoming the established method of choice to correct large bone defects with several recent studies demonstrating promising results. The high coefficient of friction of these implants provides structural support for femoral and tibial components. The high degree of porosity has excellent potential for bone ingrowth and long-term biologic fixation. Several published series, although with relatively small cohorts of patients, have reported good short-term results with trabecular metal cones for major femoral and tibial bony defects in revision TKA. In a recent study, 16 femoral and 17 tibial cones were reviewed at an average follow up of 33 months (range, 13 to 73 months) the mean Knee Society Score improved from 42 pre-operatively to 83 at last follow up with an improvement of the functional score from an average of 34 to 66 (p<0.0001). Radiological follow up revealed no evidence of loosening or migration of the constructs. No evidence of complications were noted in correlation with the use of trabecular metal cones