The role of vacuum mixing on the reduction of porosity and on the clinical performance of cemented total hip replacements remains uncertain. We have used paired femoral constructs prepared with either hand-mixed or vacuum-mixed cement in a cadaver model which simulated intra-operative conditions during cementing of the femoral component. After the cement had cured, the distribution of its porosity was determined, as was the strength of the cement-stem and cement-bone interfaces.

The overall fraction of the pore area was similar for both hand-mixed and vacuum-mixed cement (hand 6%; vacuum 5.7%; paired t-test, p = 0.187). The linear pore fractions at the interfaces were also similar for the two techniques. The pore number-density was much higher for the hand-mixed cement (paired t-test, p = 0.0013). The strength of the cement-stem interface was greater with the hand-mixed cement (paired t-test, p = 0.0005), while the strength of the cement-bone interface was not affected by the conditions of mixing (paired t-test, p = 0.275). The reduction in porosity with vacuum mixing did not affect the porosity of the mantle, but the distribution of the porosity can be affected by the technique of mixing used.

Bone-cement shrinkage has never been quantified in a stem/cement/femur construct. We observed gaps around femoral stems in transverse sections of stem/cement/femur constructs; a greater proportion of stem/cement (s/c) interface gaps were found around grit blasted sections of stems than satin finished sections. If s/c gap formation were a shrinkage artifact then mantles with few s/c interface gaps must manifest shrinkage elsewhere, at the c/b interface or voids. ‘Mould-gaps’ at a c/b interface have been described previously but not quantified. We analysed the area of gaps at both interfaces. We hypothesised 1) Total gap area was the same for all transverse sections. 2) Satin sections had greater c/b gap areas than grit sections.

Transverse sections of stem/cement/femur constructs were processed to highlight gap areas. Five stems had a satin finish (Ra 0.75 um) and five were proximally grit-blasted (Ra 5.3 um). Sections were coated with matt black spray paint and then polished with emery paper. This process left all interface gaps and voids filled with black paint, which facilitated digital imaging. Gaps were visually identified and measured using Image-Pro. Gap areas for each transverse section were normalised by the area of cement in that section.

Gaps were not evenly distributed; there was obvious localisation at both interfaces. No significant difference found between surface finishes in total gap area ((satin 3.1% ± 1.4):(grit 3.4% ± 1.5)), supporting our first hypothesis. S/c gap areas were significantly greater around grit blasted sections ((satin 0.1% ± 0.4):(grit 1.9% ± 1.7) p< 0.0001). C/b gap areas were significantly greater around satin finished sections ((satin 2.3% ± 1.3):(grit 1.0% ± 0.9) p< 0.0001), supporting our second hypothesis.

Shrinkage can localise into large interface gaps; which must lead to stress concentrations. C/b gaps are potentially benign as they can fill with bone. Cement failure at points of s/c contact would generate debris hindering bone formation.

We have compared the interface morphology at the stem-cement interface of standard Charnley stems with a satin finish (Ra = 0.75 μm) with identical stems which had been grit-blasted over their proximal third (Ra = 5.3 μm) to promote a proximal bond. The stems were cemented into cadaver femora using conventional contemporary cementing techniques. After transverse sectioning, we determined the percentage of the perimeter of the stem which had a gap at the interface.

There were substantial gaps (mean 31.4 ± 17.1%) at the stem-cement interface in the grit-blasted region. This fraction was significantly (paired t-test, p = 0.0054) higher than that found around the contralateral satin-finished stems (mean 7.7 ± 11.7%). Although studies of isolated metal-cement interfaces have shown that the bond strength can increase with surface roughness it cannot be assumed that this effect will be observed under clinical conditions.