Introduction: The purpose of this study is to evaluate the clinical and radiogra phic outcome of patients with secondary osteoarthritis of the hip, who underwent custom-made cementless THA.

Methods: Between January 1994 and June 1997, 98 prim ary cementless custom-made THA’s were performed in 76 patients with secondary osteoarthritis and reviewed at mean 6 years follow-up (range: 4 – 7.5 years). Nine patients had a previous femoral osteotomy. There were 69 females and seven males. The mean age at operation was 54 years (40 – 73 years). Custom-made, 125 mm-long, titanium femoral components with blasted surface were fabricated based on the computerized tomography.

Results: The mean Harris Hip Score improved from 43 to 95 points. 97 patients (99%) had more than 80 points for total score, and 2 patients (2%) had thigh pain at the latest follow-up. Radiographically, 86 hips (87%) showed obviously extensive bone ongrowth onto the middle part of the stem while 8 hips (9%) showed stable fibrous fixation. Four hips (4%) were unstable: more than 2 mm subsidence in 2 hips and more than 2 degrees varus migration in 2 hips. Of these 4 hips, 2 had intraoperative cracks of the poximal femur and 2 had varus positioning of the stem.

Discussion and conclusion: Cementless THA has been advocated to enhance fit and fill of variable hip geometry. However, some clinical studies failed to show that custom implants significantly improve clinical success or implant longevity because their surface finish was not optimal. Custom-made titanium femoral components with blasted surface showed good clinical results. The reasons for radiolographical failures were because of intraoperative technical errors and these might be derived from 125 mm-long stem with maximum canal fill. A shorter stem may be an option because it may improve the feasibility of stem insertion and the distal fill.

We report two cases of surface deterioration of a zirconia ceramic femoral head associated with phase transformation after total hip arthroplasty. One head was retrieved at revision due to recurrent dislocation after six years and the other because of failure of the locking mechanism of the polyethylene liner after three years. The monoclinic content of the zirconia ceramics rose from 1% to about 30% on the surface of the heads. SEM revealed numerous craters indicating extraction of the zirconia ceramics at the surface. Surface roughness increased from an initial value of 0.006 3m up to 0.12 3m. This is the first report to show that phase transformation of zirconia ceramics causes deterioration of the surface roughness of the head in vivo after total hip arthroplasty.