Fatigue of Metallic Stents: From Clinical Evidence to Computational Analysis

Fatigue strength and life prediction of lower limb venous stents under three-stage loading conditions

After the implantation of lower limb artery stents, the complex loading conditions imposed on the limb can lead to fatigue failure, which may induce inflammation and restenosis. To investigate the effect of multi-axial loading conditions on the fatigue performance of stents, five stents, namely APsolute Pro (APbott Vascular, USA), Complete SE (Medtronic, USA), Protégé EverFlex (PE3, USA), Pulsar-35 (Biotronik, Germany), and E-luminexx-B (Bard, USA), were analyzed based on the finite element method (FEM). Besides, their fatigue strength was determined under three levels of loading conditions, including tension-bending-torsion and compression-bending-torsion. Based on that, the fatigue life of these stents was predicted. The results showed that based on the nominal stress method, tension-bending-torsion loading had a more significant impact on the fatigue life of stents than compression-bending-torsion loading. Besides, two different types of initial cracks were analyzed by the fracture mechanics method. The results suggested that both the initial crack and the external load were the main causes of stent fatigue fractures. Compared with the loading nature, the influence of the initial crack on stent fatigue life was more significant. Under the same loading condition, the APsolute Pro stent had the longest fatigue life, while the E-luminexx-B stent had the shortest. Moreover, the mechanism of stent fatigue failure was revealed by exploring the fatigue performance and life prediction of stents under complex loading conditions. These findings have important implications for improving the structural design of stents and their clinical selection.

Fatigue analysis of canine tracheal stents using the finite element method

This study aimed to evaluate fatigue of three stent designs when various forces are applied and perform a comparative analyses. A computer simulation using the finite element method was performed. In particular, we constructed a three-dimensional finite element model of nitinol stents with three designs (S6: single-woven wire, wire diameter: 0.006 inch; D6: double-woven wire, wire diameter: 0.006 inch, and D7: double-woven wire, wire diameter: 0.007 inch) that are used to treat canine tracheal collapse (TC). The stents were subjected to a 200 mmHg compression force, a pure torsion force in a perpendicular direction, and a bending-torsion force combining perpendicular and axial forces. The von Mises stress was calculated to evaluate the extent of stent displacement, and Goodman diagrams were plotted to compare fatigue life cycles. D7 exhibited a longer fatigue life compared to S6 and D6. Under compression, pure torsion, and bending-torsion forces, displacement was the smallest for D7, followed by D6 and S6. Similarly, the fatigue life was the longest for D7, followed by D6 and S6. S6 showed the greatest displacement when subjected to external forces; among stents designed using the same wire, D6 displayed less displacement than S6, and D7 exhibited superior fatigue life when subjected to varying degrees of force. This study showed that the structural stability and fatigue life of stents could be effectively compared using finite element method D7 has the greatest stability and structural rigidity under cyclic load.

Numerical Simulation of Dynamic Degradation and Fatigue Damage of Degradable Zinc Alloy Stents

Current research on the fatigue properties of degradable zinc alloy stents has not yet considered the issue of the fatigue life changing with material properties during the dynamic degradation process. Therefore, in this paper, we established a fatigue damage algorithm to study the fatigue problem affected by the changing of material properties during the dynamic degradation process of the stent under the action of pulsating cyclic loading. Three models: the dynamic degradation model, the dynamic degradation model under pulsating cyclic loading, and the coupled model of fatigue damage and dynamic degradation, were developed to verify the effect of fatigue damage on stent life. The results show that fatigue damage leads to a deeper degree of inhomogeneous degradation of the stent, which affects the service life of the stent. Fatigue damage is a factor that cannot be ignored. Therefore, when studying the mechanical properties and lifetime of degradable stents, incorporating fatigue damage into the study can help more accurately assess the lifetime of the stents.

FEM Simulations of Fatigue Crack Initiation in the Oligocrystalline Microstructure of Stents

For over two decades, vascular stents have been widely used to treat clogged vessels, serving as a scaffold to enlarge the narrowed lumen and recover the arterial flow area. High-purity oligocrystalline austenitic steel is usually applied for the production of stents. Despite the popularity and benefit of stenting, it still may cause serious clinical adverse issues, such as in-stent restenosis and stent fracture. Therefore, the study of the mechanical properties of stents and in particular the prediction of their life cycles are in the focus of materials research. In our contribution, within the finite element method, a two-scale model of crack initiation in the microstructure of stents is elaborated. The approach is developed on the basis of the physically based Tanaka-Mura model (TMM), considering the evolution of shear bands during the crack initiation phase. The model allows for the analysis of the microstructure with respect to the life cycles of real materials. The effects of different loading conditions, grain orientation, and thickness of the specimen on Wöhler curves were analysed. It was found that the microstructural features of oligocrystals are very sensitive to different loading conditions with respect to their fatigue behaviour and play a major role in fatigue crack initiation. Different grain-orientation distributions result in qualitative and quantitative differences in stress distribution and in the number of cycles for crack initiation. It was found that presence of a neutral zone in the cut-out of the microstructure under three-point-bending loading conditions changes the qualitative and quantitative patterns of stress distribution and affects the number of cycles for crack initiation. It was found that under both tensile and bending loading conditions, thicker specimens require more cycles for crack initiation. The Wöhler curves for crack initiation in oligocrystalline microstructures of stents could be compared with the ones in the experiment, taking into account that for high cyclic fatigue (HCF), typically, more than 70% of the cycles refer to crack initiation. The developed numerical tools could be used for the material design of stents.

Relevant Choices Affecting the Fatigue Analysis of Ni-Ti Endovascular Devices

Ni-Ti alloys are widely used for biomedical applications due to their superelastic properties, which are especially convenient for endovascular devices that require minimally invasive insertion and durable effects, such as peripheral/carotid stents and valve frames. After crimping and deployment, stents undergo millions of cyclic loads imposed by heart/neck/leg movements, causing fatigue failure and device fracture that can lead to possibly severe consequences for the patient. Standard regulations require experimental testing for the preclinical assessment of such devices, which can be coupled with numerical modeling to reduce the time and costs of such campaigns and to obtain more information regarding the local state of stress and strain in the device. In this frame, this review aimed to enlighten the relevant choices that can affect the outcome of the fatigue analysis of Ni-Ti devices, both from experimental and numerical perspectives.

Effects of Tapered-Strut Design on Fatigue Life Enhancement of Peripheral Stents

Peripheral stent could fracture from cyclic loadings as a result of our blood pressures or daily activities. Fatigue performance has therefore become a key issue for peripheral stent design. A simple yet powerful tapered-strut design concept for fatigue life enhancement was investigated. This concept is to move the stress concentration away from the crown and re-distribute the stresses along the strut by narrowing the strut geometry. Finite element analysis was performed to evaluate the stent fatigue performance under various conditions consistent with the current clinical practice. Thirty stent prototypes were manufactured in-house by laser with a series of post-laser treatments, followed by the validation of bench fatigue tests for proof of concept. FEA simulation results show that the fatigue safety factor of the 40% tapered-strut design increased by 4.2 times that of a standard counterpart, which was validated by bench tests with 6.6-times and 5.9-times fatigue enhancement at room temperature and body temperature, respectively. Bench fatigue test results agreed very well with the increasing trend predicted by FEA simulation. The effects of the tapered-strut design were significant and could be considered as an option for fatigue optimization of future stent designs.

Patient-Specific Numerical Simulations of Endovascular Procedures in Complex Aortic Pathologies: Review and Clinical Perspectives

The endovascular technique is used in the first line treatment in many complex aortic pathologies. Its clinical outcome is mostly determined by the appropriate selection of a stent-graft for a specific patient and the operator's experience. New tools are still needed to assist practitioners with decision making before and during procedures. For this purpose, numerical simulation enables the digital reproduction of an endovascular intervention with various degrees of accuracy. In this review, we introduce the basic principles and discuss the current literature regarding the use of numerical simulation for endovascular management of complex aortic diseases. Further, we give the future direction of everyday clinical applications, showing that numerical simulation is about to revolutionize how we plan and carry out endovascular interventions.

Numerical modeling for efficiency and endurance assessment of an indirect mitral annuloplasty device

In recent years, several transcatheter systems have been introduced for treatment of common mitral regurgitation (MR). Such a system that is based on indirect mitral annuloplasty (IMA) is currently indicated for functional MR. Very few clinical studies have been performed to assess the efficiency and durability of such devices, despite their high risk of fracture resulting from ongoing exposure to large cyclic deformations. In this study, numerical models of moderate primary MR were created to test the implantation procedure of a customized IMA device and its sealing efficiency. The ability of the implanted device to reduce systolic leakage was evaluated and affirmed with a model of a more generic device. The long-term durability of the device was tested using a range of Nickel Titanium material properties. Our results demonstrated a considerable reduction in leakage for both the simplified generic device and the more detailed customized device models. The device met different fatigue criteria, confirming its resiliency and safety even after 10 years, even under the harsher conditions of primary MR. This is the first study to assess the performance and fatigue risk of IMA devices for the treatment of more complicated MR conditions. These findings may pave the way for further research to ultimately consider the device in selective cases of PMR.

Evaluation of resistance to radial cyclic loads of poly(L-lactic acid) braided stents with different braiding angles

Poly(L-lactic acid) (PLLA) braided stents have superior biocompatibility and flexibility, substituting metal stents in peripheral blood vessels. However, the radial supporting capacity of PLLA braided stent should be improved to bear the dynamic load from the peripheral artery. This paper evaluated the radial support performance of PLLA braided stents with different braiding angles after the radial cyclic loads test. The results indicate that braiding angle of stents is an important parameter affecting its ability to resist radial cyclic loads. The stent with a smaller braiding angle has better initial radial support but insufficient durability, while the stent with a larger braiding angle could maintain adequate radial support and suitable ability to resist radial cyclic loads. The theoretical analysis, verified by observing the surface morphology of filament crossover points, found that filaments of the stents with smaller braiding angles have more significant axial displacement and axial rotation angle during radial compression, which made the friction phenomenon more intense and led to insufficient ability to resist radial cyclic loads. This study could provide a meaningful idea for preparing biodegradable braided stents with suitable ability to resist radial cyclic loads.

The role of NiTi shape memory alloys in quality of life improvement through medical advancements: A comprehensive review

The significance of advanced smart materials in recent technological research and advancement is apparent from its extensive use in present day devices and instruments. Of the various smart materials in use today, the fascinating category of shape memory alloys (SMAs) is equipped with the ability to return to a previously memorized shape under certain thermomechanical or magnetic stimuli. The unique property of shape memory effect and superelasticity displayed by these materials along with good biocompatibility and corrosion resistance make them ideal for biomedical applications. The various applications of SMAs in surgical instruments, surgical implants, and assistive and rehabilitative devices have significant effect on the day to day life of people in the present age. Majority of these biomedical devices belong to the orthodontic, orthopedic, or surgical fields. Other remarkable applications of SMAs such as in the production of prostheses and orthoses designed through the biomimetic approach are also highly influential in improving the quality of life. The present paper provides an overview of the various properties of shape memory alloys and their applications in the biomedical field over the years, that have had a significant impact on the realm of medical science.

Reliable Numerical Models of Nickel-Titanium Stents: How to Deduce the Specific Material Properties from Testing Real Devices

The current interest of those dealing with medical research is the preparation of digital twins. In this frame, the first step to accomplish is the preparation of reliable numerical models. This is a challenging task since it is not common to know the exact device geometry and material properties unless in studies performed in collaboration with the manufacturer. The particular case of modeling Ni-Ti stents can be highlighted as a worst-case scenario due to both the complex geometrical features and non-linear material response. Indeed, if the limitations in the description of the geometry can be overcome, many difficulties still exist in the assessment of the material, which can vary according to the manufacturing process and requires many parameters for its description. The purpose of this work is to propose a coupled experimental and computational workflow to identify the set of material properties in the case of commercially-resembling Ni-Ti stents. This has been achieved from non-destructive tensile tests on the devices compared with results from Finite Element Analysis (FEA). A surrogate modeling approach is proposed for the identification of the material parameters, based on a minimization problem on the database of responses of Ni-Ti materials obtained with FEA with a series of different parameters. The reliability of the final result was validated through the comparison with the output of additional experiments.

Zn-Mg-WC Nanocomposites for Bioresorbable Cardiovascular Stents: Microstructure, Mechanical Properties, Fatigue, Shelf Life, and Corrosion

Zinc (Zn) and Zn alloys have been studied as potential materials for bioresorbable stents (BRSs) in the last decade due to their favorable biodegradability and biocompatibility. However, most Zn alloys lack the necessary combination of strength, ductility, fatigue resistance, corrosion rate (CR), and thermal stability needed for such applications. In this study, nanoparticles made of tungsten carbide (WC) were successfully incorporated into Zn alloyed with 0.5 wt % magnesium (Mg) and evaluated for their suitability for BRS applications. Specifically, the resulting Zn-0.5Mg-WC nanocomposite's microstructure, mechanical properties, in vitro CR, and thermal stability were evaluated. The Zn-0.5Mg-WC nanocomposite had excellent mechanical strength [ultimate tensile strength (UTS) > 250 MPa], elongation to failure (>30%), and a suitable in vitro CR (∼0.02 mm/y) for this clinical application. Moreover, the Zn-0.5Mg-WC nanocomposite survived 10 million cycles of tensile loading (stress ratio, R = 0.053) when the maximum stress was 80% of the yield stress. Its ductility was also retained during a 90-day thermal stability study, indicating an excellent shelf life. Stent prototypes were fabricated using this composition and were successfully deployed during bench testing without fracture. These results show that the Zn-0.5Mg-WC nanocomposite is a promising material for BRS applications. In vivo studies are underway to validate both biocompatibility, stent function, and degradation.

Finite element analysis in clinical patients with atherosclerosis

Endovascular plaque composition is strongly related to stent strut stress and is responsible for strut fatigue, stent failure, and possible in-stent restenosis. To evaluate the effect of plaque on artery wall resistance to expansion we performed in silico analysis of atherosclerotic vessels. We generated finite element models from in vivo intravascular ultrasound virtual histology images to determine local artery surface stiffness and determined which plaque structures have the greatest influence. We validated the predictive capacity of our modeling approach by testing an atherosclerotic peripheral artery ex vivo with pressure-inflation testing at physiological pressures ranging from 10 to 200 mmHg. For this purpose, the in silico deformation of the arterial wall was compared to that observed ex vivo. We found that calcification had a positive effect on surface stiffness with fibrous plaque and necrotic core having negative effects. Additionally, larger plaque structures demonstrated significantly higher average surface stiffness and calcification located nearer the lumen was also shown to increase surface stiffness. Therefore, more developed plaques will have greater resistance to expansion and higher stent strut stress, with calcification located near the lumen further increasing stress in localized areas. Thus, it may be expected that such plaque structures may increase the likelihood of localized stent strut fracture.

Computational and experimental mechanical performance of a new everolimus-eluting stent purpose-built for left main interventions

Left main (LM) coronary artery bifurcation stenting is a challenging topic due to the distinct anatomy and wall structure of LM. In this work, we investigated computationally and experimentally the mechanical performance of a novel everolimus-eluting stent (SYNERGY MEGATRON) purpose-built for interventions to large proximal coronary segments, including LM. MEGATRON stent has been purposefully designed to sustain its structural integrity at higher expansion diameters and to provide optimal lumen coverage. Four patient-specific LM geometries were 3D reconstructed and stented computationally with finite element analysis in a well-validated computational stent simulation platform under different homogeneous and heterogeneous plaque conditions. Four different everolimus-eluting stent designs (9-peak prototype MEGATRON, 10-peak prototype MEGATRON, 12-peak MEGATRON, and SYNERGY) were deployed computationally in all bifurcation geometries at three different diameters (i.e., 3.5, 4.5, and 5.0 mm). The stent designs were also expanded experimentally from 3.5 to 5.0 mm (blind analysis). Stent morphometric and biomechanical indices were calculated in the computational and experimental studies. In the computational studies the 12-peak MEGATRON exhibited significantly greater expansion, better scaffolding, smaller vessel prolapse, and greater radial strength (expressed as normalized hoop force) than the 9-peak MEGATRON, 10-peak MEGATRON, or SYNERGY (p < 0.05). Larger stent expansion diameters had significantly better radial strength and worse scaffolding than smaller stent diameters (p < 0.001). Computational stenting showed comparable scaffolding and radial strength with experimental stenting. 12-peak MEGATRON exhibited better mechanical performance than the 9-peak MEGATRON, 10-peak MEGATRON, or SYNERGY. Patient-specific computational LM stenting simulations can accurately reproduce experimental stent testing, providing an attractive framework for cost- and time-effective stent research and development.

Evaluation of the role of peripheral artery plaque geometry and composition on stent performance

Peripheral stent fracture is a major precursor to restenosis of femoral artery atherosclerosis that has been treated with stent implantation. In this work, we validate a workflow for performing in silico stenting on a patient specific peripheral artery with heterogeneous plaque structure. Six human cadaveric femoral arteries were imaged ex vivo using intravascular ultrasound virtual histology (IVUS-VH) to obtain baseline vessel geometry and plaque structure. The vessels were then stented and the imaging repeated to obtain the stented vessel lumen area. Finite element (FE) models were then constructed using the IVUS-VH images, where the material property constants for each finite element were calculated using the proportions of each plaque component in the element, as identified by the IVUS-VH images. A virtual stent was deployed in each FE model, and the model lumen area was calculated and compared to the experimental lumen area to validate the modeling approach. The model was then used to compare stent performance for heterogeneous and homogeneous artery models, to determine whether plaque geometry or composition had added effects on stent performance. We found that the simulated lumen areas were similar to the corresponding experimental values, despite using generic material constants. Additionally, the heterogeneous and homogeneous lumen areas were also similar, implying that plaque geometry is a stronger predictor of stent expansion performance than plaque composition. Comparing stent stress and strain for heterogeneous and homogeneous models, it was found that stress from these two models had a strong linear correlation, while the strain correlation was weaker but still present. This implies that stent performance may be predicted with a simple homogeneous material models accounting for overall geometry of the plaque, providing that stent fatigue is calculated using stress criteria.

Fatigue behavior of stent in tapered arteries: The role of arterial tapering and stent material

Stenting has achieved great success in treating cardiovascular diseases due to its high efficiency and minimal invasiveness. However, fatigue of stents severely limits its long-term outcome. In this article, finite element method was adopted to study the effects of arterial tapering and stent material on the fatigue performance of stents. A series of tapered vessels with different taper levels and two sets of stents with different materials were modeled. The Goodman diagram was used to evaluate the fatigue resistance of stents. Results showed that the fatigue resistance of stents can be extremely improved by simply changing stent material. In addition, the taper of the arteries had an important influence on the fatigue resistance of the stent. The fatigue life of the stent will be shortened with the increase of the arterial taper. The method that predicted stent fatigue life in tapered vessels can help clinicians select stents that are more suitable for tapered vessels and help stent engineers design stents that are more resistant to fatigue.

Predictive Numerical Simulations of Double Branch Stent-Graft Deployment in an Aortic Arch Aneurysm

Total endovascular repair of the aortic arch represents a promising option for patients ineligible to open surgery. Custom-made design of stent-grafts (SG), such as the Terumo Aortic^® RelayBranch device (DB), requires complex preoperative measures. Accurate SG deployment is required to avoid intraoperative or postoperative complications, which is extremely challenging in the aortic arch. In that context, our aim is to develop a computational tool able to predict SG deployment in such highly complex situations. A patient-specific case is performed with complete deployment of the DB and its bridging stents in an aneurysmal aortic arch. Deviations of our simulation predictions from actual stent positions are estimated based on post-operative scan and a sensitivity analysis is performed to assess the effects of material parameters. Results show a very good agreement between simulations and post-operative scan, with especially a torsion effect, which is successfully reproduced by our simulation. Relative diameter, transverse and longitudinal deviations are of 3.2 ± 4.0%, 2.6 ± 2.9 mm and 5.2 ± 3.5 mm respectively. Our numerical simulations show their ability to successfully predict the DB deployment in complex anatomy. The results emphasize the potential of computational simulations to assist practitioners in planning and performing complex and secure interventions.

Feasibility of using bulk metallic glass for self-expandable stent applications

Self-expandable stents are widely used to restore blood flow in a diseased artery segment by keeping the artery open after angioplasty. Despite the prevalent use of conventional crystalline metallic alloys, for example, nitinol, to construct self-expandable stents, new biomaterials such as bulk metallic glasses (BMGs) are being actively pursued to improve stent performance. Here, we conducted a series of analyses including finite element analysis and molecular dynamics simulations to investigate the feasibility of using a prototypical Zr-based BMG for self-expandable stent applications. We model stent crimping of several designs for different percutaneous applications. Our results indicate that BMG-based stents with diamond-shaped crowns suffer from severe localization of plastic deformation and abrupt failure during crimping. As a possible solution, we further illustrate that such abrupt failure could be avoided in BMG-based stents without diamond shape crowns. This work would open a new horizon for a quest toward exploiting superior mechanical and functional properties of metallic glasses to design future stents. © 2016 Wiley Periodicals, Inc. J Biomed Mater Res Part B: Appl Biomater, 105B: 1874-1882, 2017.