Static and fatigue properties of two new low-viscosity PMMA bone cements improved by vacuum mixing

The Recent Revolution in the Design and Manufacture of Cranial Implants: Modern Advancements and Future Directions

Large format (i.e., >25 cm) cranioplasty is a challenging procedure not only from a cosmesis standpoint, but also in terms of ensuring that the patient's brain will be well-protected from direct trauma. Until recently, when a patient's own cranial flap was unavailable, these goals were unattainable. Recent advances in implant computer-aided design and 3-dimensional (3-D) printing are leveraging other advances in regenerative medicine. It is now possible to 3-D-print patient-specific implants from a variety of polymer, ceramic, or metal components. A skull template may be used to design the external shape of an implant that will become well integrated in the skull, while also providing beneficial distribution of mechanical force in the event of trauma. Furthermore, an internal pore geometry can be utilized to facilitate the seeding of banked allograft cells. Implants may be cultured in a bioreactor along with recombinant growth factors to produce implants coated with bone progenitor cells and extracellular matrix that appear to the body as a graft, albeit a tissue-engineered graft. The growth factors would be left behind in the bioreactor and the graft would resorb as new host bone invades the space and is remodeled into strong bone. As we describe in this review, such advancements will lead to optimal replacement of cranial defects that are both patient-specific and regenerative.

Simulation of radical polymerization of methyl methacrylate at room temperature using a tertiary amine/BPO initiating system

A model was developed for the polymerization of methyl methacrylate at room temperature. The model used both free volume and empirical models for propagation, termination and several side reactions.

Hydrazone-bearing PMMA-functionalized magnetic nanocubes as pH-responsive drug carriers for remotely targeted cancer therapy in vitro and in vivo

To develop vehicles for efficient chemotherapeutic cancer therapy, we report a remotely triggered drug delivery system based on magnetic nanocubes. The synthesized magnetic nanocubes with average edge length of around 30 nm acted as cores, whereas poly(methyl methacrylate) (PMMA) was employed as an intermediate coating layer. Hydrazide was then tailored onto PMMA both for doxorubicin (DOX) loading and pH responsive drug delivery via the breakage of hydrazine bonds. The successful fabrication of the pH responsive drug carrier was confirmed by transmission electron microscopy, Fourier transform infrared spectroscopy, thermogravimetric analysis, and magnetic hysteresis loops, respectively. The carrier was stable at neutral environment and doxorubicin released at pH of 5.0. Cell viability assay and confocal laser scanning microscopy observations demonstrated that the loaded DOX could be efficiently released after cellular endocytosis and induced cancer cells apoptosis thereby. More importantly, the carrier could be guided to the tumor tissue site with an external magnetic field and led to efficient tumor inhibition with low side effects, which were reflected by magnetic resonance imaging (MRI), change of tumor size, TUNEL staining, and H&E staining assays, respectively. All results suggest that hydrazide-tailoring PMMA-coated magnetic nanocube would be a promising pH-responsive drug carrier for remotely targeted cancer therapy in vitro and in vivo.

Experimental investigation of the effect of surface roughness on bone-cement-implant shear bond strength

Debonding of cemented bone implants is regarded as a major contributor to complications. The relationship between shear bond strength and surface roughness has been investigated, however there are inconsistencies in the trends reported in different studies. The shear strength between poly(methyl methacrylate) bone-cement and sand blasted cobalt-chromium and titanium alloy surfaces was measured to investigate the relationship between interfacial shear strength and surface topology. Surface roughness was quantified by a power law relationship fitted to Fourier spectra as well as three traditional parameters (arithmetical average roughness (Ra), volume of interdigitation (Rr), and RMS slope (Rdq)). We found that the interfacial shear strength is directly proportional to the exponent of the surfaces power spectra (P2) and Rdq, but not to Ra and Rr. However, Rdq is shown to be critically dependent on sampling frequency, making it sensitive to measurement settings. P2 was found to be a robust measure of the surface roughness being independent of sampling frequency.

Compression strength and porosity of single-antibiotic cement vacuum-mixed with vancomycin

We evaluated the ultimate compression strength (UCS), porosity, and fracture surface roughness of 2 commercially available single-antibiotic bone cements vacuum-mixed with additional amounts of vancomycin (2, 4, 6, and 8 g). At least 8 g could be added to Palacos R + 0.5 g gentamicin (UCS = 75.04 +/- 6.64 MPa) and no more than 6 g to Simplex P + 1 g tobramycin (UCS = 78.93 +/- 4.98 MPa) to maintain a UCS above the International Organization for Standardization minimum standard (70 MPa). Increasing vancomycin concentration correlated with a decrease in porosity but showed a trend towards greater fracture surface roughness.

An in vitro optimized injectable calcium phosphate cement for augmenting screw fixation in osteopenic goats

This study reports the proportioning and standardized mixing procedures for preparing a hydroxylapatite cement (tetracalcium phosphate and dicalcium phosphate) of desired viscosity and mechanical strength reproducibly for application in trauma surgery. The behavior and the biomechanical properties of the resulting bone cement in screw augmentation were then evaluated in our osteopenic goat model. The use of a shaker standardized the mixing procedure. The optimal volume of Na2HPO4 used to prepare the injectable cement was 0.45 mL/g, with averaged in vitro compressive strength of 48.29 +/- 5.62 MPa. Histology showed increasing tightly-coupled bone apposition on the cement surface without fibrous encapsulation as observed in the screw-only controls with time in the osteopenic goat model. The cement increased the initial screw pull-out force (54.7%, p = 0.005) significantly and the energy required to failure (54.7%, p < 0.05) significantly, and remained higher than the screw-only controls after 3 months (9.8% and 20.2%, respectively) and 6 months (20.2% and 44.7%, respectively). These results imply potential in the prevention of interfacial micromotions and subsequent fibrous tissue formation at the implant-bone interface resulting in a decreased risk of implant failure. The optimized cement in this study may serve as a good candidate for augmenting fixation of osteoporotic bone.

Biological response of new activated acrylic bone cements with antiseptic properties. Histomorphometric analysis

The biological response to an acrylic bone cement cured with 4,4'-bis-dimethylamino benzydrol (BZN) as activator of reduced cytotoxicity and antiseptic properties, has been carried out and compared with that obtained for CMW 3 cement. Histomorphometrical data (undecalcified trichromic Goldner staining) were obtained by measuring the most significant variables at the bone-cement interface. Quantitative results of tissue response revealed that newly formed bone and connective tissue were maximum at 4 weeks whereas bone marrow increased with time of implantation for both cements. Statistical analysis (p < 0.05) showed no significant differences in newly formed bone and bone marrow with time and between both groups, however, connective tissue significantly decreased between 4 weeks and 12 weeks for BZN cement, and between 12 weeks and 24 weeks for CMW3. By comparing both cements at each time, lower significant percentage of connective tissue at the bone-cement interface of the BZN cement, was obtained at 12 and 24 weeks, however, a very low amount of connective tissue was found for both cements. All the results indicate that the new activated system could be applied clinically in a relatively short time, after the corresponding preclinical study.

Estimation of the minimum number of test specimens for fatigue testing of acrylic bone cement

In the literature on fatigue testing of acrylic bone cements, data sets of various sizes have been used in different test series for the same cement formulation. There are two important consequences of this situation. First, it means that some test series last much longer than others, with all the implications for the cost of testing. Second, it makes drawing conclusions about the fatigue performance of a cement, based on the results of different literature series, a problematic issue. Clearly then, a recommendation as to what should be the minimum number of test specimens to use that would allow for confidence in the results of the statistical treatment of the test results (Gmin) would be desirable. In the present work, a method that could be used to culminate in such a recommendation is described. This method involves (i) obtaining experimental fatigue test results and (ii) analyzing those results using the Weibull probability distribution function and other statistical methods. This methodology is illustrated using fatigue life results obtained from uniaxial tension-compression fatigue tests on specimens fabricated from the polymerizing dough of one commercially available acrylic bone cement. For a tolerable error of 5%, we estimated Gmin to be either 7 (if the fatigue life results are treated using the two-parameter Weibull distribution function) or 11 (if the fatigue life results are treated using the three-parameter Weibull distribution function). To be on the conservative side, we therefore recommend that Gmin be 11. Three key limitations of the methodology presented here are discussed.

Mixing of acrylic bone cement: effect of oxygen on setting properties

The present study investigates the effect of different mixing methods on the setting properties of bone cement. It was found that vacuum mixing decreased the setting time of the bone cement by nearly 2 min (10%), compared to mixing in air. Two additional experiments, in which the bone cement powders were purged with argon or oxygen, and mixed with the methyl methacrylate monomer, revealed that oxygen concentrations in the bone cement had a great effect on the setting time. The setting time increases significantly as the oxygen concentration increases, which suggests that the decrease in the setting time by vacuum mixing may be attributed to the lower oxygen levels present in the mixer. No significant effect was observed on dough time or maximum exothermic temperature by varying oxygen concentrations in the bone cement mixer.

The effect of mixing on gentamicin release from polymethylmethacrylate bone cements

We compared the release of gentamicin from 6 different commercially available, antibiotic-loaded PMMA bone cements used for vacuum- and hand-mixed cement using a Cemvac vacuum mixing system. We also measured the release of gentamicin after manual addition of the antibiotic to different commercial, unloaded bone cements after hand-mixing. The porosity of cements was reduced in all vacuum-mixed cements, as compared with hand-mixed cements, concurrent with a statistically significant reduction (3 of 6) or increase (1 of 6) in the total amounts of gentamicin released. The total gentamicin release was studied in 3 of the brands after manual addition and mixing of the antibiotics. We found that the release of antibiotics was lower than in samples made from industrial mixing. In conclusion, the manual addition and mixing of gentamicin in PMMA bone cements leads to a lower release of antibiotics than that in corresponding commercially available antibiotic-loaded cements, while vacuum-mixing only leads to a minor reduction in antibiotic release, as compared to hand-mixing.

The influence of stem insertion rate on the porosity of the cement mantle of hip joint replacements

This study investigates the effect of stem insertion rate on the porosity of the cement mantle. An experimental protocol was developed to simulate the surgical technique of cementing a prosthetic stem into the medullary canal of the femur. Cement mantle specimens were produced for three different stem insertion rates. The presence of porosity in the cement mantle was investigated. Additionally, the mechanical strength of the bone cement was assessed. Increasing the stem insertion rate did not have a significant effect on the porosity distribution within the bulk cement mantle. However, for all stem insertion rates investigated, the porosity concentration increased significantly moving from the cement/pseudofemur interface through to the stem/cement interface. In all cases, the presence of porosity significantly decreased the mechanical behaviour of the bone cement. High porosity concentration at the stem/cement interface seems to be attributed also to the rheology of the cement during implant insertion. Nevertheless, the surgeon cannot influence the formation of porosity by changing the stem insertion rate.

Fatigue testing and performance of acrylic bone-cement materials: state-of-the-art review

Over the past three decades or so, a very large volume of literature has been generated on the impact of an assortment of variables on the fatigue lifetimes of a large number of acrylic bone-cement formulations. In the present article, this literature is examined critically to reveal areas of agreement, areas of disagreement, as well as a welter of underexplored and unexplored topics. For example, there is unanimity of support for the notion that an increase in the molecular weight of the powder constituents or the fully cured cement leads to an increase in the cement's fatigue life, whereas there is disagreement as to whether vacuum mixing the cement constituents leads to an increase in the fatigue life of the fully cured cement (relative to the hand-mixed counterpart). Among the underexplored topics is systematic study of the effect of test frequency on the fatigue results, whereas determination of the optimal concentration of the antibiotic in an antibiotic-loaded cement is an example of the unexplored topics. It is pointed out that resolving the controversies, addressing the underexplored topics, and filling the lacunae will allow comprehensive evaluations of acrylic bone-cement materials to be made. This enhanced body of knowledge will prove invaluable in the continued use of acrylic bone cement as the anchoring agent in cemented arthroplasties.

Key issues involved with the use of miniature specimens in the characterization of the mechanical behavior of polymeric biomaterials--a review

This article is arranged in three parts. In the first, a brief history of the use of miniature specimens for characterizing the mechanical behavior of materials in general is given. In the second part, several trends in literature reports of small punch and small shear punch tests of ultra-high-molecular-weight polyethylene and acrylic bone cement specimens are examined critically. In this exercise, special attention is paid to one test metric; namely, the work to failure [which is the area under the punch load (P) versus punch displacement (Delta) plot up to the failure point]. In the third part of the article, seven key issues in this field are discussed. In each case, the gaps in the current knowledge base are pointed out. Among those issues are determination of sensitivity of test results to test variables, development of methods for converting P-Delta results to bulk material properties, and constitutive modeling of the mechanical behavior of a polymeric biomaterial, under both small punch and small shear punch loading.

The relationship between porosity and fatigue characteristics of bone cements

In this study, the fatigue strengths of acrylic cement prepared by various commercially available reduced pressure mixing systems were compared with the fatigue strength of cement mixed by hand (control) under atmospheric conditions. The following observations were made from this investigation. The mean fatigue strength of reduced pressure mixed acrylic bone cement is double that of cement mixed by hand using an open bowl, 11,354+/-6,441 cycles to failure for reduced pressure mixing in comparison with 5,938+/-3,199 cycles for mixing under atmospheric conditions. However, the variability in mean fatigue strengths of reduced pressure mixed bone cement is greater for some mixing devices. The variation in fatigue strengths for the different mixing techniques is explained by the different porosity distributions. The design of the reduced pressure mixing system and the technique employed during mixing strongly contribute to the porosity distribution within the acrylic bone cement. The level of reduced pressure applied during cement mixing has an effect on the fatigue strength of bone cement, but the mixing mechanism is significantly more influential.

Infection of orthopedic implants and the use of antibiotic-loaded bone cements. A review

Infections by bacteria are a serious complication following orthopedic implant surgery, that can usually only be cured by removing the implant, since the biofilm mode of growth of infecting bacteria on an implant surface protects the organisms from the host immune system and antibiotic therapy. Over the past few decades, attempts have been made to prevent and cure orthopedic implant infections by incorporating antibiotics in polymethylmethacrylate bone cements, in primary and revision surgery. However, the clinical efficacy of antibiotic-releasing bone cements is not accepted by all and the long-term exposure to low doses from antibiotic-releasing bone cements in patients is strongly related to the emerging threat of antibiotic resistance in medicine today. In this article, we start by reviewing the mechanisms governing the formation of an infectious biofilm on orthopedic implant materials, the release mechanisms and properties of clinically-used, antibiotic-loaded bone cements. The clinical efficacy of antibiotic-loaded bone cements is evaluated analyzing separatedly the prophylactic and therapeutic uses of these products.

Mixing systems and the effects of vacuum mixing on bone cement

The aim of a good cement mix is to produce bone cement that has the best mechanical properties possible in order that it can carry out its load transfer role successfully over the lifetime of the implant. The data presented shows that vacuum mixing reduces the cement porosity, which results in improved strength, and resistance to creep deformation and fatigue failure in the bone cement. It seems, however, that eliminating a high degree or all of the cement porosity may be detrimental because it leads to greater shrinkage and cracking in the material. A moderate vacuum level will improve the mechanical properties, but reduce the risk of thermal shrinkage and cracking which is seen at higher vacuum levels. In addition, the mixer design has a significant influence on the quality of the cement produced, affecting porosity, unmixed powder and subsequently the mechanical properties of the material. In the next issue we will be concluding this series of articles by covering the importance of temperature and its effects on the phases of the cement polymerisation process. Bone cement training courses are being run within hospitals by Summit Medical as part of our commitment to enhancing the skills of the perioperative practitioner and to ensuring the best long-term outcome for the patient.

Toward standardization of methods of determination of fracture properties of acrylic bone cement and statistical analysis of test results

A succinct critical review of the literature on the fatigue, fatigue crack propagation, and fracture toughness (herein collectively termed "fracture properties") of acrylic bone cement is presented, whereby it is pointed out that a plethora of test conditions have been used. This situation precludes meaningful interstudy comparisons and mitigates against a definitive delineation of the effect of a named variable on a specified fracture property. A case for standardization of test conditions is thus made, culminating in the presentation of a recommended set of such conditions. In addition, it is shown that many literature parametric studies employed inappropriate statistical methods for performing pairwise comparisons, and all these studies have not addressed the issue of possible interactions between the parameters being investigated. A methodology for addressing these deficiencies is presented in the present report, and its use is illustrated with a set of notional fatigue test results.

Principles of bone cement mixing

This is the first in a series of four consecutive articles on bone cement mixing. It aims to bring to the perioperative practitioners' attention, all of the factors that will influence the quality and reproducibility of the bone cement they produce. The series will demonstrate how perioperative practitioners can have a direct influence on the successful long-term result of a hip or knee replacement.

Relative roles of cement molecular weight and mixing method on the fatigue performance of acrylic bone cement: Simplex P versus Osteopal

The weight-average molecular weight (MW(w)) of a cement and the method used to mix its powder and liquid monomer constituents have been identified in the literature as key variables that affect mechanical properties of the fully polymerized cement that are relevant to its performance as a grouting agent in cemented arthroplasties. The goal of the present work was to identify which of these two variables exerts the greater effect in the case of fully reversed tension-compression fatigue performance. A judicious choice of cement brands, Surgical Simplex P and Osteopal, and the use of hand versus vacuum mixing, permitted this identification to be achieved. Three key observations were made in this work. First, for a given cement, the fatigue performance of vacuum-mixed specimens is far superior to that of hand-mixed ones, which may be a consequence of the substantially lower percentage areal porosity of the former specimens. Second, regardless of the mixing method, the fatigue performance of Osteopal outstrips that of Simplex P, a result that is attributed to the much higher MW(w) of the former cement. Third, hand-mixed Osteopal outperforms vacuum-mixed Simplex P (especially at low alternating stress levels), indicating that MW(w) of a bone cement is more influential than mixing method on its fatigue performance.

Radiopacity and fatigue characterization of a novel acrylic bone cement with sodium fluoride

Acrylic bone cement must provide good radiographic visibility and good long-term mechanical resistance in joint replacements. A new formulation of cement with 6% barium sulfate and 6% sodium fluoride was developed (Fluoride Bone Cement). Barium sulfate is a necessary addition to allow radiographic visibility although it reduces the mechanical strength of the material. Sodium fluoride promotes bone formation. However, its effect on the mechanical behavior is currently unknown while its influence on radiopacity can only be roughly estimated. The aim of this investigation was to establish if the new formulation would be suitable for clinical trials. In this respect, a mechanical (fatigue test) and radiographic (optical density measurements on x-ray films) characterization was performed on a typical commercially available cement with barium sulfate added and on the Fluoride Bone Cement. It was demonstrated that the fluoride cement has a (marginally) superior fatigue strength and comparable radiopacity to commercial radiopaque cements.

Properties of acrylic bone cement: state of the art review

Acrylic bone cement occupies a distinctive place in the hierarchy of synthetic biomaterials, because it is the only material currently used for anchoring the prosthesis to the contiguous bone in a cemented arthroplasty. However, the cement is not without its drawbacks. The main one is the role that it has been postulated to play in the aseptic loosening and, hence, clinical life of the arthroplasty. In turn, this role is directly related to the mechanical properties of the cement, especially the resistance to fracture of the cement in the mantle at the cement-prosthesis interface or the cement-bone interface. The present work is a detailed critical review of the recent literature on the properties of bone cement that are considered germane to its use in the stated application. The relevant properties are identified and a case is made for including each of them. Compilations of the values of these properties, obtained under clearly identified conditions, are presented for the six commercial formulations of bone cement in current popular orthopedic use. The gaps and unresolved questions in the current data base, efforts that should be made to address these issues, and research directions are covered.

Effect of mixing method on selected properties of acrylic bone cement

The present study was an investigation of the effect of the method of mixing the constituents of CMW3 bone cement on selected physical and mechanical properties of the fully polymerized cement. Five such methods were used: hand mixing; "active" vacuum mixing; mixing in a machine that allowed simultaneous mechanical mixing and centrifugation; mixing using this machine followed by application of a "passive" vacuum; and application of a passive vacuum followed by mixing in the machine. It was found that the best overall results were obtained from cement that had been mixed using the second and fifth methods and the values of the properties were: density, 1220 to 1246 kg/m3; areal porosity, 0.02 to 7.04%; ultimate compressive strength, 84 to 112 MPa; ultimate compressive strain, 5.1 to 6.4%; and compressive modulus of elasticity, 2249 to 2877 MPa.

Integrated system for preparation of bone cement and effects on cement quality and environment

We developed a prepacked mixing system for the preparation of bone cement. The system is based on mixing and collection of bone cement under a vacuum and serves as both the storage and mixing device for the cement components, thereby minimizing the exposure of the operating staff to the monomer and the risk for contamination of the cement during preparation. We evaluated the system using Palacos R and Simplex P. The cement produced was compared with cement obtained from a commercially available mixing system. Temperature evolution during curing, handling characteristics, density, and porosity of the cement obtained were analyzed. The results showed that the experimental system produces cement with physical properties (i.e., setting times and temperature, porosity, and density) equal to or better than those obtained with commercially available systems. Reducing the amount of monomer in the experimental system led to a reduction of the curing temperature without compromising the physical properties of the cements.

Pressurization of bioactive bone cement in vitro

We have developed a bioactive bone cement consisting of MgO-CaO-SiO2-P2O5-CaF2 glass-ceramic powder (AW glass-ceramic powder), silica glass powder as an inorganic filler, and bisphenol-a-glycidyl methacrylate (bis-GMA) based resin as an organic matrix. The efficacy of this bioactive bone cement was investigated by evaluating its pressurization in a 5-mm hole and small pores using a simulated acetabular cavity. Two types of acetabular components were used (flanged and unflanged sockets) and a commercially available polymethylmethacrylate (PMMA) bone cement (CMW 1 Radiopaque Bone Cement) was selected as a comparative control. Bioactive bone cement exerted greater intrusion volume in 5-mm holes than PMMA bone cement in both the flanged and unflanged sockets 10 minutes after pressurization (p < 0.05). In the small pores the bioactive and PMMA bone cements exerted almost identical intrusion volumes in flanged and unflanged sockets 10 min after pressurization. The intrusion volume in the flanged socket 10 minutes after pressurization was greater than that in the unflanged socket in all groups (p < 0.05). These results show that bioactive bone cement intrudes deeper into anchor holes than PMMA bone cement.

ESR study of MMA polymerization by a peroxide/amine system: bone cement formation

Electron spin resonance (ESR) spectroscopy was used to gain insight at the molecular level into the curing of bone cement. Methyl methacrylate was polymerized using a N,N-dimethyl-p-toluidine (TD)/benzoyl peroxide (BPO) redox system in the presence of polymethyl methacrylate (PMMA) powder. The conventional nine-line ESR spectrum for the growing polymer radical was detected at the gel stage of polymerization. While the optimum free radical concentration was observed near the equimolar amine/BPO concentration, excess amine led to a change in the chemical structure of the trapped radical and inhibited the polymerization process. At a high amine/BPO ratio the nine-line signal disappeared and a three-line nitroxide-based radical appeared. The appearance of this nitroxide signal seems to depend on the amine/BPO molar ratio and on the presence of PMMA. An excess amount of amine with respect to BPO was found to inhibit the polymerization process. When BPO was removed, the system still polymerized but with a longer gelation time and a lower radical concentration. These results demonstrate that trapped free radicals in the bulk polymerization of MMA convert to polymeric peroxides that act as initiators in bone cement. When the accelerator 4-dimethylamino phenethyl alcohol (TDOH) was used, a higher radical concentration was observed in the polymerizing system. TDOH shows potential for being a more effective accelerator than TD for bone cement curing.