Modern Porous Coatings in Orthopaedic Applications

Bone Ingrowth Around an Uncemented Femoral Implant Using Mechanoregulatory Algorithm: A Multiscale Finite Element Analysis

The primary fixation and long-term stability of a cementless femoral implant depend on bone ingrowth within the porous coating. Although attempts were made to quantify the peri-implant bone ingrowth using the finite element (FE) analysis and mechanoregulatory principles, the tissue differentiation patterns on a porous-coated hip stem have scarcely been investigated. The objective of this study is to predict the spatial distribution of evolutionary bone ingrowth around an uncemented hip stem, using a three-dimensional (3D) multiscale mechanobiology-based numerical framework. Multiple load cases representing a variety of daily living activities, including walking, stair climbing, sitting down, and standing up from a chair, were used as applied loading conditions. The study accounted for the local variations in host bone material properties and implant-bone relative displacements of the macroscale implanted FE model, in order to predict bone ingrowth in microscale representative volume elements (RVEs) of 12 interfacial regions. In majority RVEs, 20-70% bone tissue (immature and mature) was predicted after 2 months, contributing toward a progressive increase in average Young's modulus (1200-3000 MPa) of the interbead tissue layer. Higher bone ingrowth (mostly greater than 60%) was predicted in the anterolateral regions of the implant, as compared to the posteromedial side (20-50%). New bone tissue was formed deeper inside the interbead spacing, adhering to the implant surface. The study helps to gain an insight into the degree of osseointegration of a porous-coated femoral implant.

Radiographic assessment of the dynasty biofoam acetabular component with a minimum 2 years follow-up

INTRODUCTION

Acetabular components utilising novel ultraporous metal matrices have been recently introduced into clinical practice with improved interference fit, decreased stress shielding, and hope for more reliable osseointegration. 1 such example is the Dynasty Biofoam cup, which has been in clinical use for over a decade but has few reports documenting its clinical and radiographic performance.

METHODS

A single-centre retrospective study was performed evaluating 96 Dynasty Biofoam acetabular components implanted between March 2010 and August 2014 with minimum 2-year radiographic follow-up. Patients that received components for revision surgery or that had early complications postoperatively (femur fracture, prosthetic infection) were excluded. Biofoam patients were compared to 96 patients that received the Trident PSL acetabular component and were matched for age, gender, and BMI. Patient reported outcomes, component position and radiographic features of cup loosening, including radiolucent lines and sclerosis were compared among groups.

RESULTS

Patient-reported outcomes at 2 years were similar among groups. Cup anteversion was similar but inclination was significantly greater in the Biofoam group (p = 0.006). A significantly greater number of Biofoam components exhibited 2-zone (27.2%) and 3-zone (12.0%) radiolucencies compared to 0% of the Trident shells (p < 0.05). 2 Biofoam cups were revised for aseptic loosening compared to no Trident cups (p = 0.49).

DISCUSSION

Despite adequate implant survivorship, over a quarter of Biofoam cups had 2 or more radiolucent zones in early follow-up. Longer follow-up is needed to determine if the aseptic revision rate for this cup will increase.

A New Additive-Manufactured Cementless Highly Porous Titanium Acetabular Cup for Primary Total Hip Arthroplasty-Early Two-Year Follow Up

INTRODUCTION

Additive-manufacturing technologies are increasingly being used, not only to create acetabular components with porous coating architecture very similar to the complex trabecular structure of cancellous bone, but also for producing the entire implant in a single step. The aim of this study is to assess two-year clinical and radiological outcomes of a new additive-manufactured cup in primary total hip arthroplasty (THA).

MATERIALS AND METHODS

We reviewed 266 primary THAs (254 patients) performed in our institution between December 2016 and December 2018 using a new highly porous titanium acetabulum shell fabricated via additive manufacturing. Clinical and functional outcomes were measured using SF/VR-12 and HOOS JR to determine patient satisfaction with surgery. Radiographs were assessed to determine the presence of migration, radiolucency, and loosening. Patients records were reviewed to assess cup survivorship in terms of all-cause revisions and revision for aseptic cup loosening.

RESULTS

At a minimum of two-year follow up (range: 2-3.45 years), the patient cohort demonstrated significant improvement in postoperative functional scores (hip disability and osteoarthritis outcome score for joint replacement [HOOS JR.] and clinical scores (12-item short-form health survey [SF/VR-12]) (p<0.001). One cup developed progressive radiolucent lines at the prosthesis-bone interface consistent with loosening and was revised. The overall acetabular component two-year survivorship free of all-cause failure was 97.4% (95% confidence interval [CI]: 95.5-99.4%). When aseptic loosening of the acetabular component was used as the failure endpoint, the two-years survivorship rate was 99.6% (95% CI: 98.9-100%).

CONCLUSION

Highly porous titanium cementless acetabular cups produced via additive-manufacturing showed promising early clinical and radiological results in primary THA with low rates of aseptic loosening. Further follow-up studies are needed to assess the long-term survivorship and outcomes of this new acetabular component.

Metaphyseal cones in revision total knee arthroplasty: The role of stems

Aims

Metaphyseal tritanium cones can be used to manage the tibial bone loss commonly encountered at revision total knee arthroplasty (rTKA). Tibial stems provide additional fixation and are generally used in combination with cones. The aim of this study was to examine the role of the stems in the overall stability of tibial implants when metaphyseal cones are used for rTKA.

Methods

This computational study investigates whether stems are required to augment metaphyseal cones at rTKA. Three cemented stem scenarios (no stem, 50 mm stem, and 100 mm stem) were investigated with 10 mm-deep uncontained posterior and medial tibial defects using four loading scenarios designed to mimic activities of daily living.

Results

Small micromotions (mean < 12 µm) were found to occur at the bone-implant interface for all loading cases with or without a stem. Stem inclusion was associated with lower micromotion, however these reductions were too small to have any clinical significance. Peak interface micromotion, even when the cone is used without a stem, was too small to effect osseointegration. The maximum difference occurred with stair descent loading. Stress concentrations in the bone occurred around the inferior aspect of each implant, with the largest occurring at the end of the long stem; these may lead to end-of-stem pain. Stem use is also found to result in stress shielding in the bone along the stem.

Conclusion

When a metaphyseal cone is used at rTKA to manage uncontained posterior or medial defects of up to 10 mm depth, stem use may not be necessary.

Cite this article:Bone Joint Res. 2020;9(4):162–172.

Evidence of structural cavities in 3D printed acetabular cups for total hip arthroplasty

The use of three-dimensional (3D) printing to manufacture off-the-shelf titanium acetabular cups for hip arthroplasty has increased; however, the impact of this manufacturing technology is yet not fully understood. Although several studies have described the presence of structural cavities in 3D printed parts, there has been no analysis of full postproduction acetabular components. The aim of this study was to investigate the effect of 3D printing on the material structure of acetabular implants, first comparing different designs of 3D printed cups, second comparing 3D printed with conventionally manufactured cups. Two of the 3D printed cups were produced using electron beam melting (EBM), one using laser rapid manufacturing (LRM). The investigation was performed using X-ray microcomputed tomography, imaging both the entire cups and samples sectioned from different regions of each cup. All 3D printed cups showed evidence of structural cavities; these were uniformly distributed in the volume of the samples and exhibited a prevalent spherical shape. The LRM-manufactured cup had significantly higher cavity density (p = .0286), with a median of 21 cavities/mm³ compared to 3.5 cavities/mm³ for EBM cups. However, the cavity size was similar, with a median of 20 μm (p = .7385). The conventional cups showed a complete absence of distinguishable cavities. The presence of cavities is a known limitation of the 3D printing technology; however, it is noteworthy that we found them in orthopedic implants used in patients. Although this may impact their mechanical properties, to date, 3D printed cups have not been reported to encounter such failures.

Acute total hip arthroplasty in acetabular fractures using modern porous metal cup

PURPOSE

The aim of this study was to report the clinical and radiological outcome of using the modern porous metal cup in patients undergoing acute total hip arthroplasty (THA) for selected subset of acetabular fractures.

PATIENT AND METHODS

Eighteen patients with acetabular fracture underwent acute THA with modern porous metal cup from a single manufacturer. Fifteen males and three females with a mean age of 46.4 years (range 21-57 years) were ambispectively followed up for a minimum period of 48 months. All patients were evaluated clinically with Harris Hip Scores (HHS) and radiographically with serial X-rays.

RESULTS

No patient was lost to follow-up. The HHS was excellent in nine patients, good in six patients, fair in two patients, and poor in one patient. All the fractures were united and the cups were well integrated. There was no lucent line seen in any acetabular zones on the X-rays. One patient had infection, which resolved with debridement. There was one dislocation following fall, which was reduced by closed means and remained stable. One of the two patients with heterotopic ossification had restricted movement of hip but not restricting the activities of daily living. No failures of acetabular component were seen in the study.

CONCLUSION

The current study showed that the modern porous metal cup provides sufficient primary stability and appear suitable for primary THA in acute acetabular fractures at mid-term follow-up: (i) In selected fractures, acute THA can be extended to young adult patients as well. (ii) Modern porous metal cup may provide sufficient stability with or without additional fixation required.