Relatively high rates of fracture of the femoral stem of total hip replacements were seen with early designs manufactured with stainless steel. Improvements in metallurgy, alloy chemistry, materials and stem design have led to a reduction in the incidence of this complication and the occurrence of fracture with modern femoral stems is a now a rare event. However, the implantation of modern stems into heavy patients and the use of higher offset stems leads to considerable testing of the mechanical capabilities of some stem designs.

We present ten cases of fracture of modern stainless steel polished tapered stems. The fractures occur either in the neck, or in the distal half of the stem. Our clinical data suggests that heavy patients with small stems and high offsets are at risk of breaking their implants. Varus positioning of the stem in a number of cases further increases the bending moment of the stems, and the sacrifice of cement mantle thickness for implant size within narrow medullary canals may lead to the loss of proximal support. Failure analysis of the retrieved high nitrogen stainless stems also suggests there may be metallurgical factors that contribute to their failure.

On the basis of our findings, careful consideration is required when using high offset stainless steel stems in large patients.