Locking screw-plate interface stability in carbon-fibre reinforced polyetheretherketone proximal humerus plates

Biomechanical design of a new proximal humerus fracture plate using alternative materials

Comminuted proximal humerus fractures are often repaired by metal plates, but potentially still experience bone refracture, bone "stress shielding," screw perforation, delayed healing, and so forth. This "proof of principle" investigation is the initial step towards the design of a new plate using alternative materials to address some of these problems. Finite element modeling was used to create design graphs for bone stress, plate stress, screw stress, and interfragmentary motion via three different fixations (no, 1, or 2 "kickstand" [KS] screws across the fracture) using a wide range of plate elastic moduli (EP = 5-200 GPa). Well-known design optimization criteria were used that could minimize bone, plate, and screw failure (i.e., peak stress < ultimate tensile strength), reduce bone "stress shielding" (i.e., bone stress under the new plate ≥ bone stress for an intact humerus, titanium plate, and/or steel plate "control"), and encourage callus growth leading to early healing (i.e., 0.2 mm ≤ axial interfragmentary motion ≤ 1 mm; shear/axial interfragmentary motion ratio <1.6). The findings suggest that a potentially optimal configuration involves the new plate being manufactured from a material with an EP of 5-41.5 GPa with 1 KS screw; but, using no KS screws would cause immediate bone fracture and 2 KS screws would almost certainly lead to delayed healing. A prototype plate might be fabricated using alternative materials suggested for orthopedics and other industries, like fiber-metal laminates, fiber-reinforced polymers, metal foams, pure polymers, shape memory alloys, or 3D-printed porous metals.

Material Properties and Engineering Performance of Bone Fracture Plates Made from Plant Fiber Reinforced Composites: A Review

Bone fracture plates are usually made from titanium alloy or stainless steel, which are much stiffer than bone. However, overly stiff plates can restrict axial interfragmentary motion at the fracture leading to delayed callus formation and healing, as well as causing bone "stress shielding" under the plate leading to bone atrophy, bone resorption, and plate loosening. Consequently, there have been many prior efforts to develop nonmetallic bone fracture plates with customized material properties using synthetic fibers (e.g., aramid, carbon, glass) in polymer resin. Even so, plant fibers (e.g., flax, roselle, sisal) offer additional advantages over synthetic fibers, such as availability, biodegradability, less toxicity during processing, lower financial cost, and recyclability. As such, there is an emerging interest in using plant fibers alone, or combined with synthetic fibers, to reinforce polymers for various applications. Thus, this is the first review article on the material properties and engineering performance of innovative bone fracture plates made from composite materials reinforced by plant fibers alone or supplemented using synthetic fibers. This article presents material-level fiber properties (e.g., elastic modulus, ultimate strength), material-level plate properties (e.g., fatigue strength, impact toughness), and bone-plate engineering performance (e.g., overall stiffness, plate stress), as well as discussing general findings, study quality, and future work. This article may help engineers and surgeons to design, fabricate, analyze, and utilize novel bone fracture plates.

Biomechanical design optimization of proximal humerus locked plates: A review

BACKGROUND

Proximal humerus locked plates (PHLPs) are widely used for fracture surgery. Yet, non-union, malunion, infection, avascular necrosis, screw cut-out (i.e., perforation), fixation failure, and re-operation occur. Most biomechanical investigators compare a specific PHLP configuration to other implants like non-locked plates, nails, wires, and arthroplasties. However, it is unknown whether the PHLP configuration is biomechanically optimal according to some well-known biomechanical criteria. Therefore, this is the first review of the systematic optimization of plate and/or screw design variables for improved PHLP biomechanical performance.

METHODS

The PubMed website was searched for papers using the terms "proximal humerus" or "shoulder" plus "biomechanics/biomechanical" plus "locked/locking plates". PHLP papers were included if they were (a) optimization studies that systematically varied plate and screw variables to determine their influence on PHLP's biomechanical performance; (b) focused on plate and screw variables rather than augmentation techniques (i.e., extra implants, bone struts, or cement); (c) published after the year 2000 signaling the commercial availability of locked plate technology; and (d) written in English.

RESULTS

The 41 eligible papers involved experimental testing and/or finite element modeling. Plate variables investigated by these papers were geometry, material, and/or position, while screw variables studied were number, distribution, angle, size, and/or threads. Numerical outcomes given by these papers included stiffness, strength, fracture motion, bone and implant stress, and/or the number of loading cycles to failure. But, no paper fully optimized any plate or screw variable for a PHLP by simultaneously applying four well-established biomechanical criteria: (a) allow controlled fracture motion for early callus generation; (b) reduce bone and implant stress below the material's ultimate stress to prevent failure; (c) maintain sufficient bone-plate interface stress to reduce bone resorption (i.e., stress shielding); and (d) increase the number of loading cycles before failure for a clinically beneficial lifespan (i.e., fatigue life). Finally, this review made suggestions for future work, identified clinical implications, and assessed the quality of the papers reviewed.

CONCLUSIONS

Applying biomechanical optimization criteria can assist biomedical engineers in designing or evaluating PHLPs, so orthopaedic surgeons can have superior PHLP constructs for clinical use.

Carbon-fiber-reinforced polyetheretherketone orthopedic implants in musculoskeletal and spinal tumors: imaging and clinical features

Carbon-fiber-reinforced polyetheretherketone (CFR-PEEK) orthopedic implants are gaining popularity in oncologic applications as they offer many potential advantages over traditional metallic implants. From an imaging perspective, this instrumentation allows for improved evaluation of adjacent anatomic structures during radiography, computed tomography (CT), and magnetic resonance imaging (MRI). This results in improved postoperative surveillance imaging quality as well as easier visualization of anatomy for potential image-guided percutaneous interventions (e.g., pain palliation injections, or ablative procedures for local disease control). CFR-PEEK devices are also advantageous in radiation oncology treatment due to their decreased imaging artifact during treatment planning imaging and decreased dose perturbation during radiotherapy delivery. As manufacturing processes for CFR-PEEK materials continue to evolve and improve, potential orthopedic applications in the spine and appendicular skeleton increase. An understanding of the unique properties of CFR-PEEK devices and their impact on imaging is valuable to radiologists delivering care to orthopedic oncology patients in both the diagnostic and interventional settings. This multidisciplinary review aims to provide a comprehensive insight into the radiologic, surgical, and radiation oncology impact of these innovative devices.

Functional results and unfavorable events after treatment of proximal humerus fractures using a new locking plate system

BACKGROUND

Proximal humerus fractures are often treated with a fixed-angle titanium plate osteosynthesis. Recently, plates made of alternative materials such as carbon fibre-reinforced polyetheretherketone (CFR-PEEK) have been introduced. This study presents the postoperative results of patients treated with a CFR-PEEK plate.

METHODS

Patients with proximal humerus fractures treated with a CFR-PEEK plate (PEEKPower™ Humeral Fracture Plate (HFP)) were included. In follow-up examination, age and gender adjusted Constant-Murley Score (ACS), Subjective Shoulder Value (SSV), Quick Disabilities of the Arm, Shoulder and Hand Score (QDASH) and pain score (Visual Analog Scale (VAS)) were analyzed. General condition at follow-up was measured by European Quality of Life 5 Dimensions 3 Level Version (EQ-5D-3L). Range of motion was recorded. In addition, radiographs at follow-up, unfavorable events and revision rate were analyzed.

RESULTS

In total, 98 patients (66.0 ± 13.2 years, 74 females, 24 males) were reexamined. Mean follow-up was 27.6 ± 13.2 months. There were 15 2-part, 28 3-part and 55 4-part fractures. The functional scores showed good results: SSV 83.3 ± 15.6%, QDASH 13.1 ± 17.0 and ACS 80.4 ± 16.0. A 4-part-fracture, head split component, nonanatomic head shaft reposition and preoperative radiological signs of osteoarthritis were significant negative predictors for poorer clinical scores. Unfavourable events were observed in 27 patients (27.6%). Revision surgery was performed in 8 (8.2%) patients. Risk factors for an unfavourable event were female gender, age of 50 years and older, diabetes, affected dominant hand, 4-part fracture, head split and preoperative radiological signs of osteoarthritis.

CONCLUSION

There are several advantages of the CFR-PEEK plate (PEEKPower™ Humeral Fracture Plate (HFP)) such as the polyaxial screw placement and higher stability of locking screws. In summary, the CFR-PEEK plate osteosynthesis is a good alternative with comparable clinical results and some biomechanical advantages. Proximal humerus fractures show good clinical results after treatment with a CFR-PEEK plate. The revision rate and the risk of unfavorable events are not increased compared to conventional titanium plate osteosynthesis.

LEVEL OF EVIDENCE

IV.

Extra-articular migration of PEEK interference screw after anterior cruciate ligament reconstruction: a report of two cases

Background

The interference screw is the most popular device that fixes the graft for anterior cruciate ligament reconstruction, reducing the incidence of windshield effect and bungee effect. For the screw, either metallic, “bioresorbable,” or polyetheretherketone (PEEK) material is available. PEEK is popular and extensively used due to its stability, biocompatibility, radiolucency, and elastic modulus. Rare relevant complications were reported, but here, we report two cases of extra-articular migrations of PEEK interference screw from the tibial tunnel after anterior cruciate reconstruction.

Case report

An 18-year-old boy and a 56-year-old woman underwent anterior cruciate ligament reconstruction using a PEEK interference screw to fix the graft in the tibial tunnel. They suffered from screw extrusion from the tibial tunnel after 40 days and six months, respectively, with an incision rupture or palpable subcutaneous mass. They underwent a second operation and recovered well.

Conclusions

The exact incidence of extra-articular migrations of PEEK interference screws is unknown, but it seems to be quite low; despite this and its uncertain cause, the negative effects caused by the PEEK material need to be considered.

Contouring Plates in Fracture Surgery: Indications and Pitfalls

Effective fracture surgery requires contouring orthopaedic implants in multiple planes. The amount of force required for contouring is dependent on the amount and type of material contained within the plane to be altered. The type of contouring used depends on the desired plate function; for example, buttress mode often requires some degree of undercontouring, whereas compression plating may require prebending. Other reasons to contour a plate include matching patient anatomy either to maximize fixation options or to reduce implant prominence. Precontoured plates can be convenient and help to facilitate soft-tissue friendly techniques but have the potential to introduce malreduction if the plate position and fit are not carefully monitored.

Biomechanical Response under Stress-Controlled Tension-Tension Fatigue of a Novel Carbon Fiber/Epoxy Intramedullary Nail for Femur Fractures

Metallic intramedullary nails are the "gold standard" implant for repairing femur shaft fractures. However, their rigidity may eliminate axial micromotion at the fracture (causing delayed healing) and they may carry too much load relative to the femur (causing "stress shielding"). Consequently, some researchers have proposed fiber-reinforced composite nails, but only one evaluated cyclic fatigue performance. Therefore, this study assessed the cyclic fatigue response of a carbon fiber/epoxy nail with a novel ply stacking sequence of [0₂/-45/45₂/-45/0/-45/45₂/-45₂/45₂/-45/90₂] previously developed by the present authors. Nails were cyclically loaded in tension-tension at 5 Hz with a stress ratio of R=0.1 from 30% - 85% of the material's ultimate tensile strength (UTS). Thermographic stress analysis, rather than conventional fatigue testing, was used to obtain high cycle fatigue strength (HCFS), below which the nail can be cyclically loaded indefinitely without damage. Also, the mechanical test machine's built-in load cell and an extensometer were used to create stress-strain curves, from which the change in static E^O and dynamic E* moduli were obtained. Results showed that HCFS was 70.3% of UTS (or about 283 MPa), while E^O and E* remained at 42 GPa without any dRegradation during testing. The current nail shows potential for clinical use.

The Treatment of Proximal Humerus Fracture Using Internal Fixation with Fixed-angle Plates

BACKGROUND

Implants made of various types of material can be used for the internal fixation of fractures. Carbon fiber reinforced polyetheretherketone (CFR-PEEK) is a radiolucent material that may have advantageous handling properties compared with titanium implants.

METHODS

Seventy-six patients with proximal humerus fractures requiring surgery were randomized to receive a fixed-angle plate made out of either titanium or CFR- PEEK. To measure the functional outcome, the DASH score (Disabilities of Arm, Shoulder, and Hand; primary endpoint), the Simple Shoulder Test (SST), and the Oxford Shoulder Score (OSS) were determined in 63 patients at 6 weeks, 12 weeks, and 6 months after surgery, accompanied at each time point by radiological evaluation.

RESULTS

Both groups displayed improvement in DASH scores 6 months after surgery (CFR-PEEK: 27.5 ± 20.5; titanium: 28.5 ± 17.9; p = 0.82). Sensitivity analysis with multiple imputations confirmed this result (27.4 ± 19.2 versus 28.5 ± 16.6). The OSS and SST scores were likewise improved in both groups. All patients displayed full bony consolidation 12 weeks after surgery. In no case was material failure, secondary dislocation, or screw perforation seen. No difference was seen in the maintenance of postoperative reposition between the CFR-PEEK group and the titanium group.

CONCLUSION

The internal fixation of proximal humerus fractures with either CFR-PEEK or titanium led to clinical improvement 6 months after surgery. No clinical or radiological difference in outcomes was seen between the two groups. Because of the study design, however, the equivalence of the two interventions was not con- clusively demonstrated; a non-inferiority study would have been needed for this purpose.

Validation of a novel blinding method for measuring postoperative knee articular cartilage using magnetic resonance imaging

OBJECTIVES

To test PEEK implant-associated MRI artifacts, a method for blinding MRI readers, the repeatability of cartilage thickness measures before and 6 weeks after high tibial osteotomy (HTO), and the sensitivity to change of cartilage thickness 12 months after HTO.

MATERIALS AND METHODS

Ten patients underwent HTO using a PEEK implant and 3 T-MRI before, 6 weeks and 12 months after surgery. Masks were applied to hide implant visibility on 48 MRI pairs, which were assessed by 7 readers (blinded to time). One blinded reader measured femorotibial cartilage thickness from masked MRIs.

RESULTS

No artifacts were produced. Readers were unable to identify scans by time greater than by chance. Cartilage thickness before and 6 weeks after surgery was not significantly different and indicated excellent repeatability. Medial cartilage thickness increases 12 M postoperatively approached statistical significance (p = 0.06), with no lateral changes observed. Half of the participants had an increase in medial cartilage thickness at 12 M that exceeded the minimal detectable change. Standardized response mean values were moderate-to-large.

DISCUSSION

Postoperative measures of cartilage thickness are repeatable, consistent and sensitive to change when artifact is eliminated, and a validated blinding technique is used. These results provide proof of concept for accurately measuring increases in medial knee articular cartilage after medial opening wedge HTO.