Total hip replacement is one of the standard procedures in orthopedic surgery. Due to various reasons revision surgery (RTHR) has to be performed. In case of the revision of a cemented prosthesis stem, the bone cement has to be removed from the femoral cavity.

Conventionally the cement removal is done manually using a hammer, chisel or burr under X-ray control, causing a considerable radiation exposure for patient and the surgeon. Furthermore the risk of undesirable bone damage is high due to bad sight and access conditions, leading to complications and prolongation of the intervention. Different approaches addressing the mentioned problems were proposed, but did not achieve acceptance in clinical practice due to disadvantages concerning process controllability. Another possibility is to use a robot guided milling tool. However, to be able to control it typically a 3D reconstruction of the cement volume to be removed is necessary. Existing approaches use computed tomography based measurements combined with previously implanted markers, fluoroscopy or ultrasound based measurements, all requiring additional process steps prior to the surgery or to the actual cement removal.

The ICOS project (Impedance Controlled Surgical Instrumentation, Chair of Medical Engineering, RWTH Aachen University) investigates the approach of electrical impedance controlled, robot assisted bone cement removal, based on real time cement detection during the removal process without radiation exposure or the necessity of prior imaging or marker implanting steps. Therefore the electrical impedance is measured between the milling head mounted on the surgical mini-robot MINARO and one or more electrodes attached to the skin of the patient's thigh. An impedance variation mainly results from decreasing thickness of bone cement near the milling head contact point due to material removal. Hence the proposed method does not generate a 3D volume allowing for a milling path generation prior to the process. It requires a strategy for real time path generation using only the limited local information. Up to now, only the differentiation between bone cement and bone, and thus the cement-bone interface breakthrough, is reliably detectable. To efficiently use this information for the tool path generation, generic a-priori knowledge of the bone cement shape after removal of the prosthesis stem is used.

The concept for impedance controlled milling has been verified in first lab trials. For impedance measurements during the cement removal process the robots milling tool has been modified to achieve electrical insulation of the milling head. A strategy for online adaptive robot path planning has been implemented and tested in a Matlab/Simulink based process simulation. For all data sets a cement removal rate of about 90% with a bone removal of approximately 3% was achieved. These results confirm that it is generally possible to use only the limited local information for automated cement removal. Future work aims for a practical evaluation of the algorithm using real impedance measurement values.

This work has been funded by the German Ministry for Education and Research (BMBF) in the framework of the ICOS project under grant No. BMBF 13EZ1005.

Pertrochanteric femoral fractures are common and intramedullary nailing with a proximal femoral nail (PFNA®) is an accepted method for the surgical treatment. Accurate guide wire and subsequent hardware placement in the femoral neck is believed to be essential in order to avoid mechanical failure. Malpositioned implants may lead to rotational or angular malalignment or “cut out” in the femoral neck. Hip and knee arthritis might be a potential long-term consequence. The conventional technique might require multiple guidewire passes, and relies heavily on fluoroscopy.

A computer-assisted surgical planning and navigation system based on 2D-fluoroscopy was developed in-house as an intraoperative guidance system for navigated guide wire placement in the femoral neck and head. To support the image acquisition process, the surgeon is supported by a so-called “zero-dose C-arm navigation” module. This tool enables a virtual radiation-free preview of the X-ray images of the femoral neck and head. The aim of this study was to compare PFNA® insertion using this system to conventional implantation technique. We hypothesised that guide wire and subsequent implant placement using our software decreases radiation exposure to the minimum of two images and reduces the number of drilling attempts. Furthermore, accuracy of implant placement in comparison to the conventional method might be improved and operation time shortened.

We used 24 identical intact left femoral Sawbones® to simulate reduced pertrochanteric femoral fractures. First, we performed placement of the PFNA® into 12 Sawbones using the conventional fluoroscopic technique (group 1). Secondly, we performed placement of the PFNA® into 12 Sawbones guided by the computer-assisted surgical planning software (group 2). In each group, we first performed open and secondly minimal-invasive intramedullary nailing in six sawbones each. For minimal-invasive guide wire placement, a surgical drape imitated soft tissue coverage. Conventional and navigated technique used a C-arm fluoroscope (Siemens IsoC 3D®, Erlangen, Germany) in conventional 2D mode. Guidewire and subsequent blade placement in the femoral neck was evaluated. We documented: 1: the number of fluoroscopic images; 2: the total number of drilling attempts; 3: implant placement accuracy (3.1. Tip apex distance (TAD); 3.2. visible penetrations of the femoral neck and head; 3.3. blade-corticalis bone distance in the anteroposterior and lateral plane) and the 4: operation time.

The number of fluoroscopic single shots taken to achieve an acceptable PFNA®-blade position was reduced significantly with computer-assistance by 71.5% (p<0.001) in the open and by 72,4% (p<0.001) in the minimally invasive technique. In each operation two X-rays for final documentation were taken. The average number of drilling attempts for the computer-guided system was significantly (p<0.05) less than that of the conventional technique in the minimally invasive procedure. The average number of drilling attempts showed no difference between the computer-assisted and conventional techniques in the open procedure. Accuracy of implant placement showed no difference between the computer-assisted and the conventional group. Computer assistance significantly increased the mean operation time for fixation of pertrochanteric femoral fractures with a PFNA® by 79.8% (p<0.001) in the open technique and by 54.4% (p<0.001) in the minimally invasive technique.

Use of our computer-guided system for fixation of pertrochanteric femoral fractures by a PFNA® decreases the number of fluoroscopic single shots and of suboptimal guide wire passes while maintaining blade placement accuracy that is equivalent to the conventional technique. Computer-assisted surgery with our system increases the operation time and has just been tested in non-fractured sawbones. Although these results are promising, additional studies including fractured sawbones and cadaver models with extension of the navigation process to all steps of PFNA® introduction and with the goal of reducing the operation time are indispensable before integration of this navigation system into the clinical workflow.