Introduction. The ability to create patient-specific implants (PSI) at the point-of-care has become a desire for clinicians wanting to provide affordable and customized treatment. While some hospitals have already adopted extrusion-based 3D printing (fused filament fabrication; FFF) for creating non-implantable instruments, recent innovations have allowed for the printing of high-temperature implantable polymers including polyetheretherketone (PEEK). With interest in FFF PEEK implants growing, it is important to identify methods for printing favorable implant characteristics such as porosity for osseointegration. In this study, we assess the effect of porous geometry on the cell response and mechanical properties for FFF-printed porous PEEK. We also demonstrate the ability to design and print customized porous implants, specifically for a sheep tibial segmental defect model, based on CT images and using the geometry of triply periodic minimal surfaces (TPMS). Methods. Three porous constructs – a rectilinear pattern and gyroid/diamond TPMSs – were designed to mimic trabecular bone morphology and manufactured via PEEK FFF. TPMSs were designed by altering their respective equation approximations to achieve desired porous characteristics, and the meshes were solidified and shaped using a CAD workflow. Printed samples were mCT scanned to determine the resulting pore size and porosity, then seeded with pre-osteoblast cells for 7 and 14 days. Cell proliferation and alkaline phosphatase activity (ALP) were evaluated, and the samples were imaged via SEM. The structures were tested in compression, and stiffness and
Transforaminal lumbar interbody fusion (TLIF) using an implanted cage is the gold standard surgical treatment for disc diseases such as disc collapse and spinal cord compression, when more conservative medical therapy fails. Titanium (Ti) alloys are widely used implant materials due to their superior biocompatibility and corrosion resistance. A new Ti-6Al-4V TLIF cage concept featuring an I-beam cross-section was recently proposed, with the intent to allow bone graft to be introduced secondary to cage implantation. In designing this cage, we desire a clear pathway for bone graft to be injected into the implant, and perfused into the surrounding intervertebral space as much as possible. Therefore, we have employed shape optimization to maximize this pathway, subject to maintaining stresses below the thresholds for fatigue or yielding. The TLIF I-beam cage (Fig. 1(a)) with an irregular shape was parametrically designed considering a lumbar lordotic angle of 10°, and an insertion angle of 45° through the left or right Kambin's triangles with respect to the sagittal plane. The overall cage dimensions of 30 mm in length, 11 mm in width and 13 mm in height were chosen based on the dimensions of other commercially available cages. The lengths (la, lp) and widths (wa, wp) of the anterior and posterior beams determine the sizes of the cage's middle and posterior windows for bone graft injection and perfusion, so they were considered as the design variables for shape optimization. Five dynamic tests (extension/flexion bending, lateral bending, torsion, compression and shear compression, as shown in Fig. 2(b)) for assessing long term cage durability (10. 7. cycles), as described in ASTM F2077, were simulated in ANSYS 15.0. The multiaxial stress state in the cage was converted to an equivalent uniaxial stress state using the Manson-Mcknight approach, in order to test the cage based on uniaxial fatigue testing data of Ti-6Al-4V. A fatigue factor (K) and a critical stress (σcr) was introduced by slightly modifying Goodman's equation and von Mises yield criterion, such that a cage design within the safety design region on a Haigh diagram (Fig. 2) must satisfy K ≤ 1 and σcr ≤ SY = 875 MPa (Ti-6Al-4V yield strength) simultaneously. After shape optimization, a final design with la = 2.30 mm, lp = 4.33 mm, wa = 1.20 mm, wp = 2.50 mm, was converged upon, which maximized the sizes of the cage's windows, as well as satisfying the fatigue and
Introduction. Dl-α-Tocopherol (VE)-blended non-crosslinked UHMWPE has been developed as a bearing surface material for knee prostheses due to the radical scavenging capabilities of vitamin E and has demonstrated a low wear rate in knee simulator testing [1,2]. In previous our study, VE-blended, crosslinked UHMWPE has demonstrated a low wear rate in hip simulator testing [3, 4]. As the radical scavenging capabilities also reduce the crosslinking degree of the material, multiple dose crosslinking has been investigated. However, these crosslinked UHMWPE materials may have different mechanical properties, as each crosslinking process, especially the annealing condition, is different. Additionally, there is little information about VE-blended, crosslinked UHMWPE with different annealing conditions. In this study, the effect of annealing temperature was investigated with regard to tensile strength, crosslink density, and crystallinity of VE blended, crosslinked UHMWPE. Method. VE blended samples were manufactured via direct compression molding following the blending of UHMWPE resin powder (GUR1050, Ticona Inc.) with VE (dl-α-tocopherol, Eisai Co. Ltd.) at 0.3wt%. The virgin samples were derived similarly, but without the addition of VE. Both materials underwent crosslinking by irradiation via a 10MeV electron beam at 300kGy and were then heat treated at several temperatures (25, 80, 110, 130 and 150 °C) for 24 hours. Gel content, which can be interpreted as cross-link density, was determined by measuring the weight of the samples before and after soaking in decahydronaphthalene at 150 °C for twelve days. Tensile tests were carried out following JIS K 7113, with the cross head speed set at 50 mm/min. Crystallinity was determined by using DSC and integrating over the enthalpy curve from 80 to 150 °C and normalizing with the enthalpy of melting for 100% crystalline polyethylene. Result. Fig. 1 shows the gel content of UHMWPE samples after crosslinking. Raising the annealing temperature caused an increase in the gel content regardless the VE content. Additionally, among samples with the same annealing temperature, VE samples had the lower gel content. Fig. 2 shows the
Patellar fractures account for approximately 1% of all fractures. Open reduction and internal fixation is recommended to restore extensor continuity and articular congruity. However, complications such as nonunion and symptomatic hardware, still exist. Furthermore, there is a risk of re-fracturing of the healed bone during the removal of the implants. Magnesium (Mg), a biodegradable metal, has elastic moduli and compressive
Additive manufacturing (AM) techniques have gained attraction in orthopedic implant design with their ability to create unique shapes and structures. Depending on the application, there are different mechanical properties required. This study evaluated the mechanical properties of direct metal laser sintered (DMLS) Titanium alloy (Ti6Al4V) with and without hot isostatic pressure (HIP) treatment. Three dimensional computer modeling and the DMLS manufacturing assisted in building net or near-net samples for testing. The material testing consisted of uniaxial tension, Charpy impact, rotating beam fatigue (RBF), density, and hardness. Two sets of Ti6Al4V samples were created for testing using a DMLS process and stress relieved in a vacuum furnace prior to removal from the build platform. One set of samples were HIP treated. The two sets of samples were tested and the material properties of the non-HIP treated samples were compared to those with HIP treatment. Tension testing was conducted on fifteen (15) samples per treatment according to ASTM E8/E8M on as-built samples designed to a round specimen 3 per the standard. Fifteen (15) Charpy impact samples per treatment were built to near-net shapes. A low stress grind was performed on all surfaces and a notch was placed in the sample to comply with ASTM E23 and testing was performed in accordance with the standard. Fifteen (15) samples were built per treatment and machined for RBF per ISO 1143. RBF was performed on all samples at a frequency of 100 Hz with run out conditions of 10M cycles or failure. Density and hardness was measured on three (3) samples from each set using Archimedes' Principle and Rockwell hardness techniques respectively. The average (standard deviation) tensile strengths between the two groups were statistically different (p < 0.05). The non-HIP treated samples had an average ultimate strength of 956(10) MPa,
Introduction. Lipped liners have the potential to decrease the rate of revision for instability after total hip replacement since they increase the jumping distance in the direction of the lip. However, the elevated lip also may reduce the Range of Motion and may lead to early impingement of the femoral stem on the liner. It is unclear whether the use of a lipped liner has an impact on the level of lever-out moments or the contact stresses. Therefore, the aim of the current study was to calculate these values for lipped liners and compare these results to a conventional liner geometry. Materials and Methods. 3D Finite Element studies were conducted comparing a ceramic lipped liner prototype and a ceramic conventional liner both made from BIOLOX. ®. delta. The bearing diameter was 36 mm. To apply loading, a test taper made of titanium alloy was bonded to a femoral head, also made from BIOLOX. ®. delta. Titanium was modeled with a bilinear isotropic hardening law. For the bearing contact a coefficient of friction of both 0.09 or 0.3 was assumed to model a well and poorly lubricated system. Frictionless contact was modeled between taper and liner. Pre-load was varied between 500 N and 1500 N and applied along the taper axis. While keeping pre-load constant, lever-out force was applied perpendicular to the taper axis until subluxation occurred. Liners were fixed at the taper region. Lever-out moment, equivalent plastic strain and von Mises stress of the taper, bearing contact area and contact area between taper and liner was evaluated. Results. With increasing pre-load, larger lever-out moment, equivalent plastic strain, contact area between taper and liner and bearing contact area was found for both liner designs. However, von Mises stresses were nearly constant but slightly exceeded
AM Open Cell porous Ti Structures were investigated for compressive strength, morphology (i.e. pore size, struts size and porosity), and wear resistance with the aim to improve design capability at support of implant manufacturing. Specimens were manufactured in Ti6Al4V using a SLM machine. Struts sizes had nominal diameters of 200µm or 100µm, pores had nominal diameters of 700µm, 1000µm or 1500µm. These dimensions were applied to three different open-cell geometrical configurations: one with unit-cells based on a regular cubic arrangement (Regular), one with a deformed cubic arrangement (Irregular), and one based on a fully random arrangement (Fully Random). Morphological analysis was performed by image analysis applied onto optical and SEM acquired pictures. The analyses estimated the maximum and minimum Feret pores diameter, and the latter was used as one of the key parameters to describe the interconnected network of pores intended for bone colonization. Outcome revealed the systematic oversizing of the actual struts diameter Vs designed diameter; by opposite min. Feret diameters of the pores resulted significantly smaller than nominal pore diameters, thus better fitting within the range of pores dimension acknowledged to favor the osseointegration. Consequently, the actual total porosity is also reduced. Many technologic factors are responsible for the morphologic differences design vs actual, among these the influence of melting pool dimension, the struts orientation during building and the layer thickness have a significant impact. Mechanical compression was performed on porous cylinder samples. Test revealed the
INTRODUCTION. Wear induced osteolysis, material property degradation and oxidation remain a concern in cobalt chrome on polyethylene THR. ECIMA is a cold-irradiated, mechanically annealed, vitamin E blended HXLPE developed to maintain mechanical properties, minimise wear and improve long-term oxidation resistance. This study aimed to compare the in-vitro wear rate and mechanical properties of three different acetabular liners; UHMWPE, HXLPE and ECIMA. METHODS. Twelve liners (Corin, UK) underwent a 3 million cycle (mc) hip simulation. Three UHMWPE (GUR1050, Ø32 mm, γ sterilised), three HXLPE (GUR1020, Ø40 mm, 75 kGy γ, EtO sterilised) and six ECIMA (0.1 wt% vitamin E GUR1020, Ø40 mm, 120 kGy γ, mechanically annealed, EtO sterilised) liners articulated against CoCrMo femoral heads (Corin, UK). Wear testing was performed in accordance with ISO 14242 parts 1 and 2, in calf serum, with a maximum force of 3.0 kN and at a frequency of 1 Hz. Volumetric wear rate was determined gravimetrically. ASTM D638 type V specimens were machined from ECIMA material for uniaxial tension testing. Ultimate tensile
Introduction. The ability to manufacture implants at the point-of-care has become a desire for clinicians wanting to provide efficient patient-specific treatment. While some hospitals have adopted extrusion-based 3D printing (fused filament fabrication; FFF) for creating non-implantable instruments with low-temperature plastics, recent innovations have allowed for the printing of high-temperature polymers such as polyetheretherketone (PEEK). Due to its low modulus of elasticity, high
INTRODUCTION. Avascular necrosis (AVN) of the femoral head (FH) initiates from biological disruptions in the bone and may progress to mechanical failure of the hip. Mechanical and structural properties of AVN bone have not been widely reported, however such understanding is important when designing therapies for AVN. Brown et al.[1] assessed mechanical properties of different regions of AVN FH bone and reported 52% reduction in
Purpose. The purpose of this study is to analyse regional differences in the microstructural and mechanical properties of the distal femur depending on osteoarthritic changes using micro-images based on finite element analysis. Materials and Methods. Distal femur specimens were obtained from ten donors composed of 10 women with OA (mean age of 65 years, ranging from 53 to 79). As controls, the normal distal femur was sampled from age and gender matched donors consisting of 10 women(mean age of 67 years, ranging from 58 to 81). The areas of interest were six regions of the condyles of the femur(Lateral-Anterior, Middle, Posterior; Medial=Anterior, Middle, Posterior). A total of 20 specimens were scanned using the micro-CT system. Micro-CT images were converted to micro-finite element model using the mesh technique, and micro-finite element analysis was then performed for assessment of the mechanical properties. Results. Trabecular bones from the distal femur in control and OA groups exhibited different microstructural and mechanical properties in the same region. BV/TV, Tb.N, Tb.S and
Introduction. Originally, the vertical expandable titanium rib (VEPTR™) was developed to treat children with Thoracic insufficiency syndrome secondary to fused ribs and congenital scoliosis. Over the years its usage has widen and is currently being used to treat all etiology of early onset scoliosis (EOS). A major draw back remains the size of the titanium VEPTR™ implant. In keeping with the new trend of chrome-cobalt alloy (CoCr). spinal implants, we set out to explore if redesigning the VEPTR™ was mechanically sound. The aim of this study was twofold. Firstly, we investigate the mechanical properties of a VEPTR™ made with CoCr alloy compared to that of titanium alloy. Secondly we investigated how much we could down size the VEPTR™. Materials & Methods. Finite element analyses were performed on 3 different VEPTR™ designs (rod diameter of 6mm, 5mm and 4mm) subjected to a compressive load of 500N (equivalent to a 50Kg child). For each configuration, two materials, titanium alloy and chrome-cobalt alloy, were used. Maximum Von Mises stress distribution (VMSD), plastic strain (PS) and total displacement (TD) of the VEPTR™ were measured as indicators of mechanical properties of the implant. Results. Results for the maximum Von Mises stress distribution (VMSD), plastic strain and total displacement (TD) can be seen on the table 1. Discussion. Results confirm that
Effectiveness and long term stability of hip resurfacing and total hip arthroplasty for osteoarthritis patients are still debated nowadays. Several clinical and biomechanical issues have to be considered, including pain relief, return to function, femoral neck fractures, impingement and prosthesis loosening. Normally, patients with hip arthroplasties are facing gait adaptation and at risk of fall. Sudden impact loading and twisting during sideway falls may lead to femoral fractures and joint failures. The purposes of this study are (i) to investigate the stress behavior of hip resurfacing and total hip arthroplasty, and (ii) to predict pattern of femoral fractures during sideway falls and twisting configurations. Computed tomography (CT) based images of a 54-year old male were used in developing a 3D femoral model. The femur model was designed to be inhomogeneous material as defined by Hounsfield Unit of the CT images. CAD data of hip arthroplasties were imported and aligned to represent RHA and THA femur modelas shown in Fig.1. Prosthesis stem is modeled as Ti-6Al-4V material while femoral ball as Alumina properties. Meanwhile, RHA implant is assigned as Co-Cr-Mo material. Four types of loading and boundary conditions were assigned to demonstrate different falling (FC) and twisting (TC) configurations (see Fig.2). Finite element analysis combined with a damage mechanics model was then performed to predict bone fractures in both arthroplasty models. Different loading magnitudes up to 4BW were applied to extrapolate the fracture patterns. Prediction of femoral fracture for RHA and THA femurs are discussed in corresponding to maximum principal stress and damage formation criterion. The load bearing strain was set to 3000micron, the physiological bone loading that leads to bone formation. The test strength was wet to 80% of the
Orthopaedic reconstruction procedures to combat osteoarthritis, inflammatory arthritis, metabolic bone disease and other musculoskeletal disorders have increased dramatically, resulting in high demand on the advancement of bone implant technology. In the past, joint replacement operations were commonly performed primarily on elderly patients, in view of the prosthesis survivorship. With the advances in surgical techniques and prosthesis technology, younger patients are undergoing surgeries for both local tissue defects and joint replacements. This patient group is now more active and functionally more demanding after surgery. Today, implanted prostheses need to be more durable (load-bearing), they need to better match the patient's original biomechanics and be able to survive longer. Additive manufacturing (AM) provides new possibilities to further combat the problem of stress-shielding and promote better bone remodelling/ingrowth and thus long term fixation. This can be accomplished by matching the varying strain response (stiffness) of trabecular or subchondral bone locally at joints. The purpose of this research is therefore to determine whether a porous structure can be produced that can match the required behaviour and properties of trabecular bone regardless of skeletal location and can it be incorporated into a long-term implant. A stochastic structure visually similar to trabecular bone was designed and optimised for AM (Figure 1) and produced over a range of porosities in multiple materials, Stainless Steel 316, Titanium (Grade 23 – Ti6Al4V ELI) and Commercially Pure Titanium (Grade 2) using a Renishaw AM250 metal additive manufacturing system. Over 150 cylindrical specimens were produced per material and subjected to a compression test to determine the specimens' Elastic Modulus (Stiffness) and Compressive
Introduction. Porous scaffolds for bone ingrowth have numerous applications, including correcting deformities in the foot and ankle. Various materials and shapes may be selected for bridging an osteotomy in a corrective procedure. This research explores the performance of commercially pure Titanium (CPTi) and Tantalum (Ta) porous scaffold materials for use in foot and ankle applications under simplified compression loading. Methods. Finite element analysis was performed to evaluate von Mises stress in 3 porous implant designs: 1) a CPTi foot and ankle implant (Fig 1) 2) a similar Ta implant (wedge angle = 5°) and 3) a similar Ta implant with an increased wedge angle of 20°. Properties were assigned per reported material and density specifications. Clinically relevant axial compressive load of 2.5X BW (2154 N) was applied through fixtures which conform to ASTM F2077–11. Compressive yield and fatigue strength was evaluated per ASTM F2077–11 to compare CPTi performance in design 1 to the Ta performance of design 3. Results. FEA results indicate peak stresses at fixture contact locations. Similar designs (CPTi design 1 and Ta design 2) resulted in similar von Mises stresses (Fig 1). Increasing the wedge angle (Ta design 3) increased stress by 15%. The static compressive
Background. Calcium phosphate cement (CPC) is a promising biomaterial which can be used in numerous medical procedures for bone tissue repairing because of its excellent osteoconductivity. An injectable preparation and relatively short consolidation time are particularly useful characteristics of CPC. However, the low strength of CPC and its brittleness restrict its use. One method for toughening brittle CPC is to incorporate fibrous materials into its matrix to create a composite structure. Fibers are widely used to reinforce matrix materials in a variety of areas. Objective. We hypothesized that there must be an optimal fiber length and structure which can balance these conflicting aspects of fiber reinforcement. The purpose of this study is to prove our conjectures that adding a small amount of short fibers significantly improves the hardness and the toughness of CPC while maintaining its injectability with a syringe and that fiber morphologies that have crimps and surface roughness are favorable for reinforcing. Material and Methods. We used 3 types of short fibers of approximately 20–50 micrometer in diameter and 2 mm in length in this study: crimpy wool, crimpy polyethylene and straight polyethylene fibers. All of the materials were prepared by mixing a solvent with CPC powder with or without fiber. We grouped as follow, the control group, the wool group, the crimpy polyethylene group, the straight polyethylene group. After soaking in 37 degrees Celsius Simulated Body Fluid∗∗∗∗∗ for 1, 3, or 7 days, they were tested for each period. Impact strength test by the falling weight and compression test were performed. Result. In the impact strength test, after soaking for 1 day, impact resistance in the wool group was approximately 180 times greater than in the control group. When soaking for 3 days or more, impact resistance of wool group improve better than control group. The impact resistance of the wool group was the greatest among the four groups in soaking for 3 days. In the compression test, the
Introduction. Ability to accommodate increased range of motion is a design objective of many modern TKA prostheses. One challenge that any “high-flex friendly” prosthesis has to overcome is to manage the femorotibial contact stress at higher flexion angle, especially in the polyethylene tibial insert. When knee flexion angle increases, the femorotibial contact area tends to decrease thus the contact stress increases. For a high-flex design, considerations should be taken to control the contact stress to reduce the risk of early damage or failure on the tibial insert. This study evaluated the effect of femoral implant design on high flexion contact stress. Two prostheses from a same TKA family were compared – one as a conventional design and the other as a high-flex design. Methods. Two cruciate retaining (CR) prostheses from a same TKA product family were included in this study. The first is a conventional design for up to 125° of flexion (Optetrak CR, Exactech, USA). The second is a high-flex design for up to 145° of flexion (Logic CR, Exactech, USA). The high-flex design has a femoral component which has modified posterior condyle geometry (Figure 1), with the intent to increase femorotibial contact area and decrease contact stress at high flexion. Three sizes (sizes 1, 3, and 5) from each prosthesis line were included to represent the commonly used size spectrum. Contact stress was evaluated at 135° of flexion using finite element analysis (FEA). The CAD models were simplified and finite element models were created assuming all materials as linear elastic (Figure 2). For comparison purpose, a compressive force of 20% body weight was applied to the femoral component. The average body masses of sizes 1, 3 and 5 patients are 69.6 kg, 89.9 kg, and 106.3 kg based on the manufacture's clinical database. A nonlinear FEA solver was used to solve the simulation. Von Mises stress in the tibial insert was examined and compared between the two prostheses. Results. The high-flex design demonstrated lower tibial insert stresses compared to the conventional design, and the stress reduction is consistent across different sizes (Figure 3). The peak von Mises stress of the high-flex design was 8.6 MPa, 10.8 MPa, and 11.9 MPa for sizes 1, 3 and 5, representing a 40% to 60% decrease compared to those of the conventional design (14.3 MPa, 26.5 MPa, and 25.6 MPa respectively). Discussion/Conclusion. One limitation of the study was that no material nonlinearity was considered in the FEA, thus stress values above the