Background: As the understanding of bone repair mechanics has advanced the integrity of the bone pin interface has emerged as a key factor in determining the success of external fracture fixation. The benefits of using pins coated with Hydroxyapatite (HA) are well documented however the thickness of the conventional plasma spray coating precludes its use for modification of the surface of fine features in implants. Consequently new electro-chemical techniques for pre-coating implants with a ‘biomimetic’ HA layer using simulated body fluids (SBF) have been pioneered. In this study we test the hypothesis that varying the technique for deposition of HA by electrolysis of SBF alters the morphology of the HA surface which will modify the level of osseointegration. Method: Three alternative methods of HA coating the Barerre, Redepenning and Kumar techniques were compared. Tantalum coated stainless steel pins were coated then used to stabilise a mid-diaphyseal osteotomy in three sheep using an orthofix fixator for a period of ten weeks. Insertion and extraction torques were measured to calculate the pin performance index (PPI). Sections of the bones were then examined using scanning electron microscopy to determine the percentage of bone in contact with the pin surface and the percentage of new bone formation. Results: The different coating protocols resulted in different HA crystal morphologies. The extraction torque exceeded the insertion torque for both the Barerre and Redepenning methods and their PPI exceeds that of plasma spray coatings. The Redepenning technique was shown to perform sig-nificantly better than both the Barerre (p=0,001) and Kumar (p=0,001) techniques with 49.4% of the pin surface in contact with bone. These results were mirrored on analysis of new bone formation with the Redepen-ning technique showing 70.2% of new bone formation compared to the Barerre (55.4%) and Kumar (53.8%) methods. Conclusion: These results indicate that the Redepenning technique is the most effective for creating a bio mimetic HA coating in terms of bonding to bone and promoting new bone formation. This technique holds significant advantages over the conventional plasma spray technique for example the coating thickness can be easily controlled and additional proteins such as bone morphogenic proteins and antibiotics can be incorporated. It may therefore represent a new era in the use of HA coating.

Introduction: External fixation is used widely in the management of fractures, despite a relatively high incidence of complication, arising from pin loosening and infection. Diamond like carbon (DLC) is a low surface energy coating that can be applied to external fixator pins and may reduce biofilm formation and infection resulting in a lower incidence of pin loosening. Hydroxyapatite (HA) is well established as a coating to enhance fixation of external fixator pins. This study tests the hypothesis that HA and DLC coatings on stainless steel (SS) external fixator pin shafts modify integration of the implant with soft/hard tissues.

Materials and Methods: An Orthofix external fixator was used to stabilise a tibial osteotomy with 6 self-drilling/tapping 6mm pins in 32 skeletally mature Friesland ewes. Animals were divided into four groups; SS, DLC, HA partially coated (threads only) and HA fully coated (threads and pin shaft). Pin insertion torque was measured using a torque wrench and extraction torque similarly obtained at 10 weeks when animals underwent euthanasia. Pin performance indices (PPI) were calculated as a ratio of extraction to insertion torque x100%. Pin site 2 was preserved for hard grade resin histology and subsequent pin tissue integration analysis. Pin site 3 was used for analysis of the soft tissue pin shaft interface using transmission electron microscopy. Pin site 5 was examined for the presence of biofilm formation using scanning electron microscopy. Pin site 6 was swabbed for microbiological analysis.

Results: SS and DLC pins achieved significantly higher insertion torques compared to HA partially coated pins (p=0.001, 0.002). Both groups of HA coated pins demonstrated a significantly higher, extraction torque and therefore PPI for all pin site positions compared to SS and DLC (p< 0.001– 0.025). The epithelium was found not to be in contact with the pin shaft in all cases. No significant differences were found between the different pin groups for epidermal down growth and dermal contact. Both groups of HA coated pins showed a significantly higher percentage of new bone in direct contact with the embedded threads compared to SS and DLC pins (p< 0.001, p=0.004). The proportion of soft tissue in contact and within the thread, of fully coated HA pins was significantly lower compared to stainless steel (p=0.003, p=0.017), DLC (p=0.004, p=0.002) and HA partially coated pins (p=0.006, p=0.02). Biofilms were evident on all pins except those coated with DLC. More bacteria were observed on the fully HA coated pins. DLC had significantly lower number of bacterial colonies in culture compared to SS (p=0.028) and fully coated HA pins (p=0.005).

Discussion: Coatings of DLC and HA do have a significant affect on hard/soft tissue reactions. However coatings do not have a significant effect on epidermal down growth or dermal attachment to the pin shaft surface. DLC coated pins had the cleanest surface with no bio-film present and significantly lower numbers of bacteria present. Fully HA coated pins despite evidence of bio-film formation, bacteria and high microbiological counts had significantly higher PPI. In addition fully coated HA pins demonstrated significantly reduced amounts of soft tissue at the pin bone interface. Therefore soft tissue reactions may affect bone integration.