Factors affecting modular acetabular ceramic liner insertion: a biomechanical analysis

Feasibility of a Shape-Memory-Alloy-Actuator System for Modular Acetabular Cups

Hip implants have a modular structure which enables patient-specific adaptation but also revision of worn or damaged friction partners without compromising the implant-bone connection. To reduce complications during the extraction of ceramic inlays, this work presents a new approach of a shape-memory-alloy-actuator which enables the loosening of ceramic inlays from acetabular hip cups without ceramic chipping or damaging the metal cup. This technical in vitro study exam-ines two principles of heating currents and hot water for thermal activation of the shape-memory-alloy-actuator to generate a force between the metal cup and the ceramic inlay. Mechanical tests concerning push-in and push-out forces, deformation of the acetabular cup according to international test standards, and force generated by the actuator were generated to prove the feasibility of this new approach to ceramic inlay revision. The required disassembly force for a modular acetabular device achieved an average value of 602 N after static and 713 N after cyclic loading. The actuator can provide a push-out force up to 1951 N. In addition, it is shown that the necessary modifications to the implant modules for the implementation of the shape-memory-actuator-system do not result in any change in the mechanical properties compared to conventional systems.

Evaluating the Feasibility and Reproducibility of a Novel Insertion Method for Modular Acetabular Ceramic Liners

Modern hip implants have a modular design. In case of wear or other damage it allows surgeons to change the tribological partners, i.e., the acetabular liner and femoral ball. In both revision and primary surgery, the secure joining of the implant components is important for the success of the operation. The two components, namely the ceramic liner and hip cup, are connected via a conical press connection and should be concentrically aligned to avoid chipping. Malseated liners can reduce the life span in situ. The amount of the joining force, which is usually applied via a hammer, depends on the surgeon. In this study, an alternative joining method for acetabular ceramic liners in hip cups was investigated, which intends to make the process more reproducible and thus safer. For this purpose, a handpiece was used to apply a defined force impulse of 4 kN. For the concentric alignment of a ceramic liner in the hip cup, an adapter was developed based on findings via a qualitative finite element (FE) analysis. Insertion and pushout tests of the acetabular cup-liner connection were performed in the laboratory with the new instrument (handpiece with the connected adapter) to evaluate the functionality of the instrument and the reproducibility of the new insertion method. For comparison, liners and acetabular cups were joined using a testing machine according to the standard. The presented results demonstrate the technical proof-of-concept of the new joining method under laboratory conditions. They meet the acceptance criteria of established manufacturers, which proves the equivalency to proven methods for joining modular implant components. To verify the improvement of the new joining method compared to the conventionally used joining method, an application-oriented study with different surgeons and the new joining instrument under clinical conditions is necessary.

Clinical Outcomes, Metal Ion Levels, Lymphocyte Profiles, and Implant Survival Following Five Different Bearings of Total Hip Arthroplasty: A Mean 10-year Follow-up Study

BACKGROUND

Different bearings have been used in total hip arthroplasty (THA), but the long-term performance is still controversial. The purpose of this study was to investigate whether there are differences when comparing THAs with 5 different bearings at a long-term follow-up of more than 10 years.

METHODS

From January 2010 to May 2012, 101 THA patients (134 hips) were divided into metal-on-metal group (MoM, 31 hips), metal-on-polyethylene group (MoP, 23 hips), ceramic-on-metal group (CoM, 21 hips), ceramic-on-ceramic group (CoC, 33 hips), and ceramic-on-polyethylene group (CoP, 26 hips). The mean follow-up period was 10.3 years. The Harris hip score (HSS), Western Ontario and McMaster Universities Osteoarthritis Index scores (WOMAC), range of motion (ROM), blood cell count, and liver-kidney function were measured. Serum and urine metal ion levels were measured using high-resolution inductively coupled plasma-mass spectrometry (ICP-MS) and a blood lymphocytes analysis was counted by flow cytometry.

RESULTS

No difference was observed in the HSS, WOMAC, ROM, blood cell count, or liver-kidney function among any of the 5 groups. Metal ion levels were significantly elevated in metal-containing bearings. Flow cytometry showed that no differences were found. Revision was performed due to pseudotumor in 3 patients. The implant survival rate was 96.7% and 93.3% for the MoM and CoC groups, which was significantly lower compared with other groups.

CONCLUSIONS

Metal ion levels were elevated significantly in metal-containing bearings, especially in MoM THA patients. The implant survival rate was significantly lower in CoC and MoM THAs, which was mainly due to pseudotumor formation.

LEVEL OF EVIDENCE

Therapeutic Level II.

Surgeons’ Awareness and Impaction Technique of a Ceramic Liner into a Metal Shell

Background

In ceramic-on-ceramic total hip arthroplasty, firm locking is necessary between a ceramic liner and an acetabular metal shell to prevent dissociation of the liner from the metal shell. We evaluated surgeons’ awareness of the technique for inserting the ceramic liner and measured the impaction force applied by surgeons during the insertion of the ceramic liner.

Methods

To evaluate the awareness, we conducted a survey using a questionnaire including techniques for ceramic liner insertion. The impaction force was measured using an impaction simulator in 224 surgeons.

Results

Most surgeons answered that they cleaned and dried up the inner surface of the metal shell before inserting a ceramic liner (96.4% and 86.2%, respectively), and 74.6% checked the correct seating of the ceramic liner. However, only 23.2% correctly answered that a minimum of 2kN (a light strike) was necessary to obtain a sufficient fit between the metal shell and the ceramic liner. The impaction force was weaker than 2 kN in 9.4% of the surgeons.

Conclusions

Education about the adequate impaction force to obtain a firm fit of the ceramic liner is necessary for surgeons who perform total hip arthroplasty using ceramic-on-ceramic bearings.

Hip Resurfacing vs Total Hip Arthroplasty in Patients Younger than 35 Years: A Comparison of Revision Rates and Patient-Reported Outcomes

Background

Hip resurfacing arthroplasty (HRA) and total hip arthroplasty (THA) are two treatment options for end-stage degenerative hip conditions. The objective of this single-center retrospective cohort study was to compare implant survival and patient-reported outcomes (PROs) in young patients (≤35 years) who underwent HRA or THA.

Methods

All patients aged 35 years or younger who underwent HRA or THA with a single high-volume arthroplasty surgeon between 2004 and 2015 were reviewed. The sample included 33 THAs (26 patients) and 76 HRAs (65 patients). Five-year implant survival and minimum 2-year PROs were compared between patient cohorts.

Results

Three patients in the THA group (9%) were revised within 5 years for instability (n = 1), squeaking (n = 1), or squeaking with a ceramic liner fracture (n = 1). No patients who underwent HRA were revised. The University of California, Los Angeles, activity score, modified Harris Hip score, and Hip Dysfunction and Osteoarthritis Outcome Scores for Joint Replacement increased by 74%, 64%, and 49%, respectively, among all patients. Compared to the HRA cohort, patients who underwent THA had lower preoperative and postoperative University of California, Los Angeles, activity, modified Harris Hip score, and Hip Dysfunction and Osteoarthritis Outcome Scores for Joint Replacement scores, yet there were no differences in the absolute improvements in any of the three measures between the two groups.

Conclusions

Excellent functional outcomes were seen in young patients undergoing either HRA or THA. Although young patients undergoing THA started at lower preoperative baseline and postoperative PROs than patients undergoing HRA, both groups improved by an equal amount after surgery, suggesting that both HRA and THA afford a similar degree of potential improvement in a young population.

Preventing ceramic liner fracture after Delta ceramic-on-ceramic total hip arthroplasty

BACKGROUND

The results of total hip arthroplasty (THA) with use of Delta ceramic articulation were successful at medium term follow-up. The use of this newest ceramic has markedly reduced the incidence of ceramic head fractures, but not the incidence of ceramic liner fractures. We tested a hypothesis that the ceramic fractures are prevented by use of a metal shell with 18° inner taper angle and a stem design with a reduced neck geometry.

METHODS

We conducted a prospective multicenter study of cementless THA with use of 32/36-mm Delta ceramic bearing, Exceed ABT metal shell and Taperloc stem. We evaluated ceramic fracture, noise, clinical results, radiological changes and survival rate at a minimum of 5-year follow-up.

RESULTS

From April 2010 to February 2012, 246 patients (274 THAs) were enrolled. Among them, 224 patients (130 men and 94 women, 250 hips) were followed-up for 5-8 years (mean 6.0 years). Ceramic malseating or fracture did not occur in any patient. Eight patients (8 hips, 3.2%) reported noise. Mean Harris hip score was 84 points at the latest follow-up. All acetabular and femoral components had bone-ingrown stability. Two hips were revised due to recurrent dislocation and periprosthetic fracture. The survival rate was 99.6% at 8 years postoperatively.

CONCLUSION

Ceramic fractures can be prevented by a use of (1) 32/36-mm Delta ceramic bearing, (2) metal shell with 18° taper angle, and (2) stem with a reduced neck geometry. However, noise remains a concern of the Delta ceramic bearing.

LEVEL OF EVIDENCE

Therapeutic level II.

Long-Term Outcome on the Mal-Seating of Ceramic-on-Ceramic Articulation in Total Hip Arthroplasty

BACKGROUND

Total hip arthroplasty with ceramic-on-ceramic articulation aims to decrease wear, osteolysis, and aseptic loosening. A metal-backed ceramic liner was developed to reduce the risk of liner fracture. However, a significant number of cases of mal-seating of the metal-backed ceramic liner were observed in the 2000s, and there were concerns about their outcome. This review aims to investigate the long-term performance of the mal-seated ceramic liner.

METHODS

From July 2003 to March 2007, 35 ceramic-on-ceramic total hip arthroplasties were performed with the Trident acetabular system. Clinical assessment, radiological analysis, and outcome assessment were performed. The prevalence of liner mal-seating and its long-term outcomes were investigated.

RESULTS

There was liner mal-seating in 8 hips (22.9%). One liner was exchanged in the early postoperative period. No revision surgery was required for the remaining 7 hips at a mean follow-up of 14 years. All patients were free of hip pain with a mean Harris Hip Score of 94.7 at the most recent follow-up. No adverse event was observed.

CONCLUSION

The long-term outcomes of the mal-seated liner were favorable. However, surgeons should exercise meticulous surgical technique to achieve a properly aligned liner within the acetabular shell to minimize this potentially correctable error.

Use of a modular hip dual-mobility articulation in patients with high risk of dislocation: a relatively small-sized acetabulum in Asian patients may limit its use

BACKGROUND

Dual-mobility hip component is widely used in Europe and North America, because it effectively reduces hip dislocation in primary and revision total hip arthroplasties. However, reports were limited on the use of dual-mobility articulation in Asian populations.

PURPOSE

The aim of this retrospective study was to review the use of modular dual-mobility hip articulation in Asian patients with the high risk factor for hip dislocation. We also discussed the potential concern on the use of dual-mobility articulation in Asian patients.

METHODS

From Jan 2018 to June 2019, 17 patients were included in this study. The mean age of the patients was (73.8 ± 9.5) years (range: 57-88 years). The mean size of acetabular cup and modular DM liner were (49.5 ± 3.4) mm (range, 46-58 mm) and (40.7 ± 3.4) mm (range, 38-48 mm), respectively. The mean follow-up period was (15.8 ± 3.9) months (range, 11-24 months). The primary outcome was the rate of hip dislocation. The secondary outcomes included the Harris Hip Score. Differences were considered statistically significant at p < 0.05.

RESULTS

Hip dislocation, loosening, peri-prosthetic fractures, or intra-prosthetic dislocation was not found in the series. The mean preoperative and postoperative Harris Hip Scores were 42.2 ± 17.2 (range, 15-80) and 74.7 ± 13.5 (range, 52-97), respectively, giving a mean improvement of 32.5 ± 17.2 (range, 4-72). The improvement was statistically significant (p < 0.05).

CONCLUSIONS

In Asian patients with high risk of hip dislocation, the use of modular dual-mobility hip component produces promising outcomes without hip dislocation, but the relatively small-sized acetabulum may limit it widespread application in other populations worldwide.

TRIAL REGISTRATION

HKUCTR-2913 .

Time-dependent Viscoelastic Response of Acetabular Bone and Implant Seating during Dynamic Implantation of Press-fit Cups

Deformation of an acetabular cup implant during cementless implantation is indicative of the radial compressive forces, and such of the initial implant fixation strength. Stress relaxation in the surrounding bone tissue following implantation could reduce the deformation of the cup and thus primary implant fixation. The aim of this study was therefore to determine the early shape change of the implanted cup immediately after implantation with different press-fit levels and whether recording the force during cup impaction can be used to estimate initial cup fixation. Cup implantations into porcine acetabulae (n=10) were performed using a drop tower. The force induced by the drop weight and cup seating after each impact was recorded. Deformation of the implanted cup was determined with strain gauges over a period of 10min. Lever-out torques were measured to assess the initial fixation strength. Stress relaxation in the bone caused a reduction in cup deformation of 13.52±4.06% after 1min and 29.34±5.11% after 10min. The fixation strength increased with a higher force magnitude during impaction (R_s²=0.810, p=0.037). Reduction of the radial compressive forces due to stress relaxation of the surrounding bone should be considered during press-fit cup implantation in order to compensate for the reduced fixation strength over time. In addition, recording the implantation force could help to estimate initial fixation strength.

Characterization of dimensional, morphological and morphometric features of retrieved 3D-printed acetabular cups for hip arthroplasty

Background

Three-dimensional (3D) printing of porous titanium implants is increasing in orthopaedics, promising enhanced bony fixation whilst maintaining design similarities with conventionally manufactured components. Our study is one of the first to non-destructively characterize 3D-printed implants, using conventionally manufactured components as a reference.

Methods

We analysed 16 acetabular cups retrieved from patients, divided into two groups: ‘3D-printed’ (n = 6) and ‘conventional’ (n = 10). Coordinate-measuring machine (CMM), electron microscopy (SEM) and microcomputed tomography (micro-CT) were used to investigate the roundness of the internal cup surface, the morphology of the backside surface and the morphometric features of the porous structures of the cups, respectively. The amount of bony attachment was also evaluated.

Results

CMM analysis showed a median roundness of 19.45 and 14.52 μm for 3D-printed and conventional cups, respectively (p = 0.1114). SEM images revealed partially molten particles on the struts of 3D-printed implants; these are a by-product of the manufacturing technique, unlike the beads shown by conventional cups. As expected, porosity, pore size, strut thickness and thickness of the porous structure were significantly higher for 3D-printed components (p = 0.0002), with median values of 72.3%, 915 μm, 498 μm and 1.287 mm (p = 0.0002). The median values of bony attachment were 84.9% and 69.3% for 3D-printed and conventional cups, respectively (p = 0.2635).

Conclusion

3D-printed implants are designed to be significantly more porous than some conventional components, as shown in this study, whilst still exhibiting the same shape and size. We found differences in the surface morphologies of the groups, related to the different manufacturing methods; a key finding was the presence of partially molten particles on the 3D-printed cups.

Influence of the Acetabular Cup Material on the Shell Deformation and Strain Distribution in the Adjacent Bone-A Finite Element Analysis

In total hip arthroplasty, excessive acetabular cup deformations and altered strain distribution in the adjacent bone are potential risk factors for implant loosening. Materials with reduced stiffness might alter the strain distribution less, whereas shell and liner deformations might increase. The purpose of our current computational study was to evaluate whether carbon fiber-reinforced poly-ether-ether-ketones with a Young´s modulus of 15 GPa (CFR-PEEK-15) and 23 GPa (CFR-PEEK-23) might be an alternative shell material compared to titanium in terms of shell and liner deformation, as well as strain distribution in the adjacent bone. Using a finite element analysis, the press-fit implantation of modular acetabular cups with shells made of titanium, CFR-PEEK-15 and CFR-PEEK-23 in a human hemi-pelvis model was simulated. Liners made of ceramic and polyethylene were simulated. Radial shell and liner deformations as well as strain distributions were analyzed. The shells made of CFR-PEEK-15 were deformed most (266.7 µm), followed by CFR-PEEK-23 (136.5 µm) and titanium (54.0 µm). Subsequently, the ceramic liners were radially deformed by up to 4.4 µm and the polyethylene liners up to 184.7 µm. The shell materials slightly influenced the strain distribution in the adjacent bone with CFR-PEEK, resulting in less strain in critical regions (<400 µm/m or >3000 µm/m) and more strain in bone building or sustaining regions (400 to 3000 µm/m), while the liner material only had a minor impact. The superior biomechanical properties of the acetabular shells made of CFR-PEEK could not be determined in our present study.

Comparative analysis of current 3D printed acetabular titanium implants

BACKGROUND

The design freedom allowed by three-dimensional (3D) printing enables the production of acetabular off-the-shelf cups with complex porous structures. The only studies on these designs are limited to clinical outcomes. Our aim was to analyse and compare the designs of different 3D printed cups from multiple manufacturers (Delta TT, Trident II Tritanium and Mpact 3D Metal).

METHODS

We analysed the outer surface of the cups using scanning electron microscopy (SEM) and assessed clinically relevant morphometric features of the lattice structures using micro-computed tomography (micro-CT). Dimensions related to the cup wall (solid, lattice and overall thickness) were also measured. Roundness and roughness of the internal cup surface were analysed with coordinate measuring machine (CMM) and optical profilometry.

RESULTS

SEM showed partially molten titanium beads on all cups, significantly smaller on Trident II (27 μm vs ~ 70 μm, p < 0.0001). We found a spread of pore sizes, with median values of 0.521, 0.841 and 1.004 mm for Trident II, Delta TT and Mpact, respectively. Trident II was also significantly less porous (63%, p < 0.0001) than the others (Delta TT 72.3%, Mpact 76.4%), and showed the thinnest lattice region of the cup wall (1.038 mm, p < 0.0001), while Mpact exhibited the thicker solid region (4.880 mm, p < 0.0044). Similar roundness and roughness of the internal cup surfaces were found.

CONCLUSION

This was the first study to compare the designs of different 3D printed cups. A variability in the morphology of the outer surface of the cups and lattice structures was found. The existence of titanium beads on 3D printed parts is a known by-product of the manufacturing process; however, their prevalence on acetabular cups used in patients is an interesting finding, since these beads may potentially be released in the body.

Deformation of acetabular press-fit cups: Influence of design and surgical factors

BACKGROUND

Deformation of acetabular cups when press-fitted into an undersized cavity is inevitable due to the inhomogeneous stiffness of acetabular bone. Thinner cups or screw holes might increase the risk of high cup deformation. The aim of this study was to examine the influence of cup design and liner assembly on the deformation response during cup implantation.

METHODS

Acetabular cups with different designs were implanted into polyurethane foam models simulating the anatomical situation with nominal press-fits of 1mm and without nominal press-fits (line-to-line). Deformations were determined using a tactile coordinate measuring machine. A 3D laser scanner was used to determine the contact conditions at the cup-cavity interface. Polyethylene and ceramic liners were assembled to the implanted cups and the influence of the insertion on the deformation response evaluated. Fixation strength of the cups was determined by push-out testing.

FINDINGS

Cup deformation increased with smaller wall thickness (P < 0.037) and screw holes (P < 0.001). Insertion of ceramic liners reduced the deformation (P < 0.001), whereas polyethylene liners adapted to the deformation of the implanted cups (P > 0.999). Thin-walled cups exhibited a higher fixation strength for similar implantation forces (P = 0.011).

INTERPRETATION

Thin-walled cups achieved higher fixation strengths and might be more bone-preserving. However, in combination with screw holes and high press-fit levels, wall thickness should be considered carefully to avoid excessive cup deformations leading to potential complications during liner assembly. Line-to-line insertion of thin-walled cups should be accompanied with a rough surface coating to minimize the loss of fixation strength due to the low press-fit fixation.

Atraumatic Fracture of the BIOLOX delta Ceramic Liner in Well-Fixed Total Hip Implants

A newer alumina matrix composite ceramic (BIOLOX delta; CeramTec, Plochingen, Germany) was developed to improve resistance to wear while reducing the risk for fractures with alumina-on-alumina design. This article describes a case of fracture of the BIOLOX delta ceramic liner without history of trauma in well-fixed total hip implants. A 61-year-old woman underwent total hip replacement via the posterior approach 20 months earlier because of osteonecrosis of the femoral head. A cementless cup and a stem with a 52/36-mm BIOLOX delta couple bearing were used. The authors found signs of stripe wear on the inner surface of the ceramic liner, leading them to believe the possible cause of fracture in this patient was edge loading due to joint laxity. The authors performed revision surgery with the use of another ceramic couple-bearing implant and converted the head component from short to long (+4 mm). More cases should be collected to verify the mechanism of the fracture of the BIOLOX delta ceramic liner with a well-fixed cup. [Orthopedics. 2018; 41(6):e880-e883.].

Excellent results of large-diameter ceramic-on-ceramic bearings in total hip arthroplasty

Aims

This study reports the mid-term results of total hip arthroplasty (THA) performed using a monoblock acetabular component with a large-diameter head (LDH) ceramic-on-ceramic (CoC) bearing.

Patients and Methods

Of the 276 hips (246 patients) included in this study, 264 (96%) were reviewed at a mean of 67 months (48 to 79) postoperatively. Procedures were performed with a mini posterior approach. Clinical and radiological outcomes were recorded at regular intervals. A noise assessment questionnaire was completed at last follow-up.

Results

There were four re-operations (1%) including one early revision for insufficient primary fixation (0.4%). No hip dislocation was reported. The mean University of California, Los Angeles (UCLA) activity score, 12-Item Short-Form Health Survey (SF-12) Mental Component Summary (MCS) score, SF-12 Physical Component Summary (PCS) score, Western Ontario and McMaster Universities Osteoarthritis Index (WOMAC) score, and Forgotten Joint Score (FJS) were 6.6 (2 to 10), 52.8 (25.5 to 65.7), 53.0 (27.2 to 66.5), 7.7 (0 to 63), and 88.5 (23 to 100), respectively. No signs of loosening or osteolysis were observed on radiological review. The incidence of squeaking was 23% (n = 51/225). Squeaking was significantly associated with larger head diameter (p < 0.001), younger age (p < 0.001), higher SF-12 PCS (p < 0.001), and UCLA scores (p < 0.001). Squeaking did not affect patient satisfaction, with 100% of the squeaking hips satisfied with the surgery.

Conclusion

LDH CoC THAs have demonstrated excellent functional outcomes at medium-term follow-up, with very low revision rate and no dislocations. The high incidence of squeaking did not affect patient satisfaction or function. LDH CoC with a monoblock acetabular component has the potential to provide long term implant survivorship with unrestricted activity, while avoiding implant impingement, liner fracture at insertion, and hip instability. Cite this article: Bone Joint J 2018;100-B:1434–41.

Do rim cracks and backside grinding affect the aging kinetics of alumina-matrix composite acetabular liners?

The acetabular liner malalignment and rim impingement have been problematic issues in ceramic-on-ceramic (CoC) total hip arthroplasty (THA). Commercial ceramic liners made of alumina-matrix composite (AMC) have polished articulation and rim, and roughly ground backside with a button-like apical projection (post) to resist tilting. In this study, we hypothesized that rim cracks and backside grind critically affect the aging kinetics of tetragonal zirconia dispersed in AMC structure. We analyzed phase transformation in the zirconia phase and residual stresses in the alumina matrix during aging by Raman and fluorescence spectroscopy. We demonstrated that the polished surfaces showed environmental stability in vitro, while the roughly-ground backside showed a significant stability loss and tensile stress accumulation as a consequence of enhancing the inter-component fixation between the liner and the metallic shell. Rim cracking locally produced a preferential transformation at the tip and the surrounding of the crack. Note that the tensile stress concentration at the crack tip was counteracted by the phase transformation after a few hours of aging. This suggests the presence of a time lag in vivo before further transformation around the crack could provide a crack shielding effect in the material. © 2018 Wiley Periodicals, Inc. J. Biomed. Mater. Res. Part B, 2018. © 2018 Wiley Periodicals, Inc. J Biomed Mater Res Part B: Appl Biomater 107B: 791-798, 2019.

Biomechanical behavior of modular acetabular cups made of poly-ether-ether-ketone: A finite element study

After total hip arthroplasty, stress-shielding is a potential risk factor for aseptic loosening of acetabular cups made of metals. This might be avoided by the use of acetabular cups made of implant materials with lower stiffness. The purpose of this numerical study was to determine whether a modular acetabular cup with a shell made of poly-ether-ether-ketone or poly-ether-ether-ketone reinforced with carbon fibers might be an alternative to conventional metallic shells. Therefore, the press-fit implantation of modular cups with shells made of different materials (Ti6Al4V, poly-ether-ether-ketone, and poly-ether-ether-ketone reinforced with carbon fibers) and varying liner materials (ceramics and ultra-high-molecular-weight polyethylene) into an artificial bone cavity was simulated using finite element analysis. The shell material had a major impact on the radial shell deformation determined at the rim of the shell, ranging from 17.9 µm for titanium over 92.2 µm for poly-ether-ether-ketone reinforced with carbon fibers up to 475.9 µm for poly-ether-ether-ketone. Larger radial liner deformations (up to 618.4 µm) occurred in combination with the shells made of poly-ether-ether-ketone compared to titanium and poly-ether-ether-ketone reinforced with carbon fibers. Hence, it can be stated that conventional poly-ether-ether-ketone is not a suitable shell material for modular acetabular cups. However, the radial shell deformation can be reduced if the poly-ether-ether-ketone reinforced with carbon fiber material is used, while deformation of ceramic liners is similar to the deformation in combination with titanium shells.

Ceramic-on-ceramic bearing fractures in total hip arthroplasty

Aims

Ceramic-on-ceramic (CoC) bearings in total hip arthroplasty (THA) are commonly used, but concerns exist regarding ceramic fracture. This study aims to report the risk of revision for fracture of modern CoC bearings and identify factors that might influence this risk, using data from the National Joint Registry (NJR) for England, Wales, Northern Ireland and the Isle of Man.

Patients and Methods

We analysed data on 223 362 bearings from 111 681 primary CoC THAs and 182 linked revisions for bearing fracture recorded in the NJR. We used implant codes to identify ceramic bearing composition and generated Kaplan-Meier estimates for implant survivorship. Logistic regression analyses were performed for implant size and patient specific variables to determine any associated risks for revision.

Results

A total of 222 852 bearings (99.8%) were CeramTec Biolox products. Revisions for fracture were linked to seven of 79 442 (0.009%) Biolox Delta heads, 38 of 31 982 (0.119%) Biolox Forte heads, 101 of 80 170 (0.126%) Biolox Delta liners and 35 of 31 258 (0.112%) Biolox Forte liners. Regression analysis of implant size revealed smaller heads had significantly higher odds of fracture (chi-squared 68.0, p < 0.001). The highest fracture risk was observed in the 28 mm Biolox Forte subgroup (0.382%). There were no fractures in the 40 mm head group for either ceramic type. Liner thickness was not predictive of fracture (p = 0.67). Body mass index (BMI) was independently associated with revision for both head fractures (odds ratio (OR) 1.09 per unit increase, p = 0.031) and liner fractures (OR 1.06 per unit increase, p = 0.006).

Conclusions

We report the largest independent study of CoC bearing fractures to date. The risk of revision for CoC bearing fracture is very low but previous studies have underestimated this risk. There is good evidence that the latest generation of ceramic has greatly reduced the odds of head fracture but not of liner fracture. Small head size and high patient BMI are associated with an increased risk of ceramic bearing fracture. Cite this article: Bone Joint J 2017;99-B:1012–19.

Revision Total Hip Arthroplasty for Fractured Ceramic Bearings: A Review of Best Practices for Revision Cases

BACKGROUND

Total hip arthroplasty revision for a fractured ceramic bearing is rare but offers unique challenges. The purpose of this review was to provide a summary of existing literature on fractured ceramic bearings.

METHODS

Two authors performed a literature search of the MEDLINE OVID and PubMed databases with the following search terms: ceramic, fracture, total hip arthroplasty, and revision.

RESULTS

The search identified 228 articles of which 199 were selected for review.

CONCLUSIONS

It is mandatory to perform a complete synovectomy and thorough debridement of the fractured ceramic fragments. A well-fixed acetabular component should be removed if either the locking mechanism is damaged or the component is malpositioned. If the femoral stem taper is damaged, the femoral stem should be removed. However, if minimal damage is present, the femoral stem may be retained and revised using a fourth generation ceramic head with a titanium sleeve. Metal bearings should be avoided and revision with ceramic bearings should be performed whenever possible.

Shell design and reaming technique affect deformation in mobile-bearing total hip arthroplasty acetabular components

Press-fit acetabular components are susceptible to rim deformation. The inherent variability within acetabular reaming techniques may generate increased press-fit and, subsequently, additional component deformation. The purpose of this study was to analyze the insertion and deformation characteristics of acetabular components designed for dual-mobility systems based on component design, size, and reaming technique. Shell deformation was quantified in a validated worst-case scenario foam pinch model. Thin-walled, one-piece, and modular dual-mobility shells of varying size were implanted in under- and over-reamed cavities with insertion force measured and shell deformation assessed using digital image correlation. Increased shell size resulted in larger rim deformation in one-piece components, with a reduction in press-fit by 1 mm resulting in up to 48% reduction in insertion forces and between 23% and 51% reduction in shell deformation. Lower insertion forces and deformations were observed in modular components. Variability in acetabular reaming plays a significant role in the ease of implantation and component deformation in total hip arthroplasty. Modular components are less susceptible to deformation than thin-walled monoblock shells. Care should be taken to avoid excessive under-reaming, particularly in the scenario of large shell size and high-density patient bone stock.

Effect of Inner Taper Angle of Acetabular Metal Shell on the Malseating and Dissociation Force of Ceramic Liner

BACKGROUND

Malseating of ceramic liner appeared as a matter of concern in multibearing metal, although multibearing cup can be coupled with hard liners as well as polyethylene liner. In this metal shell, the inner taper angle should be 10° for the modularity, while standard metal shells for ceramic liner have an inner taper angle of 18°. However, there has been no study in the effect of taper angle to the risk of malseating. We evaluated whether the taper angle of metal shell might affect the malseating of ceramic liner, and dissociation force of ceramic liner from metal shell.

METHODS

Three surgeons manually inserted ceramic liners into two designs of metal shell with different tapers angles (10° and 18°). We compared malseating rates of ceramic liners and push-out strengths, which means dissociation force of the ceramic liner from the metal shell, between these two metal shell designs.

RESULTS

The malseating rates in 10° metal shell were higher than those in 18° metal shell (23.3% vs 0%, P < .05). The mean dissociation force (1148.8 ± 46.7 N) in 10° taper cup was higher than that (389.7 ± 108.3 N) in 18° taper cup (P < .01).

CONCLUSION

Our results suggest that surgeon should be cautious about malseating of ceramic liner when using multi-bearing metal shell with inner taper angle of 10°.

CLINICAL RELEVANCE

When surgeon use multi-bearing metal shell with inner taper angle of 10°, our results suggest that surgeon should be cautious about malseating of ceramic liner.

Do the Reasons for Ceramic-on-ceramic Revisions Differ From Other Bearings in Total Hip Arthroplasty?

BACKGROUND

Despite widespread use of ceramic-on-ceramic (CoC) in total hip arthroplasty (THA) during the past 10 years, little is known about why revisions are performed in hips with this bearing or the time elapsed before revision.

QUESTIONS/PURPOSES

The purposes of this study were: (1) Do the reasons for first revision differ between CoC bearings and other bearing couples? (2) Does the time to revision differ between CoC and other bearing couples? (3) Are there unique reasons for revisions of CoC bearings?

METHODS

All members of the Société Française de Chirurgie Orthopédique et Traumatologique (SoFCOT) who performed ≥ 30 revisions per year were invited to participate in this multicenter, prospective, observational study. Our data represent 12% of the revision procedures performed in France. A total of 2107 first revisions of THA (from January 2010 to December 2011) were done in 2107 patients (1201 females [57%] and 906 males [43%]; median age, 73 years; age range, 17-104 years) at the time of surgery after a median of 11 years (range, 0 day-42 years) after the primary THA. There were 238 of 2107 (11%) CoC, 148 of 2107 (7%) metal-on-metal (MoM), and 1721 of 2017 (82%) metal-on-polyethylene (MoP) bearings.

RESULTS

The reasons for reoperation differed according to the bearing component: (1) for the MoP reference bearing (odds ratio [OR]; 95% confidence interval), cup loosening occurred in 698 of 1721 hips (41%), periprosthetic fracture in 220 of 1721 hips (13%), and osteolysis in 213 of 1721 hips (12%); (2) for CoC, cup loosening occurred in 41 of 238 hips (17%) (OR, 0.31 [0.22-0.43; p < 0.001), infection in 39 of 238 hips (16%) (OR, 1.63 [1.12-2.37]; p = 0.01), and dislocation in 23 of 238 hips (10%) (OR, 0.9 [0.57-1.42]; p = 0.9); (3) for MoM, cup loosening occurred in 28 of 148 hips (19%) (OR, 0.34 [0.22-0.52]; p < 0.001), adverse reaction to metallic debris in 26 of 148 hips (18%) (OR, 18.12 [9.84-33.4]; p < 0.001), and infection in 16 of 148 hips (11%) (OR, 1 [0.59-1.73]; p = 0.9). In comparison with MoP, osteolysis was rarely the reason for revision in CoC (four of 238 hips [2%]; OR, 0.12 [0.05-0.33]; p < 0.001), but this bearing was frequently revised because of iliopsoas irritation (18 of 238 hips [8%]; OR, 4.9 [2.7-9]; p < 0.001). The time elapsed before revision differed between bearings: median of 3 years (range, 3 days to 28 years) for CoC and 4 years (range, 14 days to 37 years) for MoM versus a median 13 years (range, 0 day to 42 years) for MoP (p < 0.001). Thirty-seven of the 238 revisions (16%) were directly related to ceramic use (ceramic breakage [n = 23], squeaking [n = 6], impingement [n = 7], incorrect ceramic insert insertion [n = 1]). No factors were identified that contributed to breakage of the 12 bulk ceramic components (eight heads, four inserts, four of 12 Delta ceramic). No factors were associated with squeaking, iliopsoas irritation, or impingement, but component orientation was not assessed.

CONCLUSIONS

The reasons and time to first revision differed between CoC and other bearings. CoC THAs are revised earlier and are sensitive to mechanical problems such as impingement, squeaking, and ceramic rupture that did not disappear with introduction of Delta ceramics and large-diameter (≥ 36 mm) bearings. CoC was rarely revised for osteolysis, but a high rate of iliopsoas irritation requires further investigation.

LEVEL OF EVIDENCE

Level III, therapeutic study.

Canted seating of the Stryker Modular Dual Mobility liner within a Trident hemispherical acetabular shell

A 75-year-old woman who suffered a left femoral neck fracture underwent a left total hip arthroplasty using a Stryker Trident (Kalamazoo, MI) hemispherical acetabular shell and Modular Dual Mobility (MDM) metal liner. Post-operative radiographs demonstrated canted seating of the liner. The patient was taken immediately back to the operating room where the acetabular liner appeared well seated superiorly but was in a canted position inferiorly. Removal and replacement was performed and post-operative radiographs demonstrated complete seating. Subsequent follow up at 6 months demonstrated good clinical function with no adverse radiographic findings. Canted seating is a potential complication of the MDM metal liner. Providers should be aware of potential incomplete seating inferiorly despite the superior portion of the liner being well seated.

Do alumina matrix composite bearings decrease hip noises and bearing fractures at a minimum of 5 years after THA?

BACKGROUND

Ceramic-on-ceramic bearing couples are theoretically attractive in total hip arthroplasty (THA) because of low wear, but concerns regarding ceramic fracture and squeaking have arisen. Improved material properties of newer alumina matrix composite (AMC) materials, known as Delta ceramics, may reduce these risks. In addition, the use of thinner liners and larger femoral heads may be helpful clinically to lower the rate of dislocation. However, limited short-term clinical results are available and intermediate-term effects are unclear.

QUESTIONS/PURPOSES

(1) What is the frequency of bearing-related complications (dissociation, fracture, and noise) with ceramic-on-ceramic AMC bearings in cementless THA? (2) What other complications arose in patients treated with these bearings? (3) What are the Harris hip scores (HHS) and survivorship free from reoperation and revision at a minimum of 5 years after cementless THA performed with AMC bearings?

METHODS

Over a 9-month period in 2009, one surgeon performed 125 THAs, of which 100 (80% of the total) were performed with cementless, AMC bearings. During the period in question, the exclusion criteria for this implant were primary THAs with severe acetabular or femoral bone defect and revision THAs. Of these, 94 hips (95%) in 91 patients were available for analysis at a minimum of 5 years (range, 5-6 years), because five patients (six hips) had died. Mean age at the time of arthroplasty was 55 ± 14 years. Prostheses with an identical design and Biolox(®) Delta ceramics were used in all patients. Noise was classified into squeaking, clicking, grinding, and popping. Ceramic fracture, dislocation, and any other complications associated with the use of AMC ceramics were also investigated. Clinical evaluation included the modified HHS preoperatively and at each followup. Survivorship free from reoperation and revision was calculated using the Kaplan-Meier method.

RESULTS

Of 91 patients, four developed bearing-related complications, including one with liner dissociation despite initial square seating and three with clicking. No patients had ceramic fractures. A single event of perioperative dislocation occurred in one patient and postoperative periprosthetic fracture occurred in two hips. Mean HHS improved from 56 to 93 points at the final followup (p < 0.001). Survivorship at 5 years free from reoperation and revision was 96.8% and 97.9%, respectively.

CONCLUSIONS

Improved material properties combined with the possible use of larger diameter heads make AMC ceramics a promising alternative bearing option with seemingly comparable clinical outcomes reported by others with conventional ceramic bearings. Despite these encouraging results, however, meticulous technical precautions such as square seating and proper impaction in particular should be taken during liner insertion, because we did observe one liner dissociation and several patients with hip noises.

LEVEL OF EVIDENCE

Level IV, therapeutic study.

The influence of metallic shell deformation on the contact mechanics of a ceramic-on-ceramic total hip arthroplasty

Total hip arthroplasty of ceramic-on-ceramic bearing combinations is increasingly used clinically. The majority of these implants are used with cementless fixation that a metal-backing shell is press-fitted into the pelvic bone. This usually results in the deformation of the metallic shell, which may also influence the ceramic liner deformation and consequently the contact mechanics between the liner and the femoral head under loading. The explicit dynamic finite element method was applied to model the implantation of a cementless ceramic-on-ceramic with a titanium shell and subsequently to investigate the effect of the metallic shell deformation on the contact mechanics. A total of three impacts were found to be necessary to seat the titanium alloy shell into the pelvic bone cavity with a 1 mm diameter interference and a 1.3 kg impactor at 4500 mm s(-1) velocity. The maximum deformation of the metallic shell was found to be 160 µm in the antero-superior and postero-inferior direction and 97 µm in the antero-inferior and postero-superior direction after the press-fit. The corresponding values were slightly reduced to 67 and 45 µm after the ceramic liner was inserted and then modified to 74 and 43 µm under loading, respectively. The maximum deformation and the maximum principal stress of the ceramic liner were 31 µm and 144 MPa (tensile stress), respectively, after it was inserted into the shell and further increased to 52 µm and 245 MPa under loading. This research highlights the importance of the press-fit of the metallic shell on the contact mechanics of the ceramic liner for ceramic-on-ceramic total hip arthroplasties and potential clinical performances.

Extraction of a well fixed but fractured ceramic acetabular liner

Ceramic fractures have been reported to occur in hip replacements, but the techniques used to extract a well fixed but fractured component are not commonly described. We present a case of ceramic liner fracture and validate a modification of a previously reported extraction technique that allowed us to save the acetabular cup and insert a polyethylene liner. With an increasing trend in ceramic bearing usage, it is likely that the number of ceramic liner fractures will increase and therefore knowledge of successful extraction techniques will be desirable.

Wear of a composite ceramic head caused by liner fracture

Third-generation composite ceramics (eg, Delta; DePuy Orthopaedics, Warsaw, Indiana; Ceramtec, Plochingen, Germany) have greatly improved material characteristics compared with second-generation products. This case report presents a patient after total hip arthroplasty with a fractured ceramic liner and a heavily worn ceramic head (both third-generation ceramics) retrieved 9 months after surgery. The patient showed no symptoms in the involved hip but presented to the hospital because of other symptoms. The failure was caused by a tilted liner that was overlooked after surgery and fractured consecutively. Rim chipping and splitting were the 2 fracture modes observed for the liner. The head did not fracture completely because of its high strength but became roughened by the ceramic fragments, causing major wear of the metal back of the cup. The phase transformation of the zirconium grains from tetragonal to monoclinic in the aluminum oxide matrix was shown by radiographic diffraction analysis in the heavily worn areas of the head. This transformation increases the fracture strength of the head. Metal debris caused by a roughened ceramic head without fracture is an unreported phenomenon for third-generation ceramic bearings in hip arthroplasty. This case shows that proper impaction of the ceramic liner into the metal shell to prevent later tiling during reduction is as important as correct component positioning. If a tilted ceramic liner is observed postoperatively, the position must be corrected immediately to prevent the major consequences observed in this patient.

Fracture of ceramic bearing surfaces following total hip replacement: a systematic review

Ceramic bearing surfaces are increasingly used for total hip replacement, notwithstanding that concern is still related to ceramic brittleness and its possible mechanical failure. The aim of this systematic review is to answer three questions: (1) Are there risk factors for ceramic component fracture following total hip replacement? (2) Is it possible to perform an early diagnosis of ceramic component failure before catastrophic fracture occurs? (3) Is it possible to draw guidelines for revision surgery after ceramic components failure? A PubMed and Google Scholar search was performed and reference citations from publications identified in the literature search were reviewed. The use of 28 mm short-neck femoral head carries an increased risk of fracture. Acetabular component malposition might increase the risk of ceramic liner fractures. Synovial fluid microanalysis and CT scan are promising in early diagnosis of ceramic head and liner failure. Early revision is suggested in case of component failure; no consensus exists about the better coupling for revision surgery. Ceramic brittleness remains a major concern. Due to the increased number of ceramic on ceramic implants, more revision surgeries and reports on ceramic components failure are expected in the future. An algorithm of diagnosis and treatment for ceramic hip failure is proposed.

Do obesity and/or stripe wear increase ceramic liner fracture risk? An XFEM analysis

BACKGROUND

Hypothesized risk factors for fracture of ceramic liners include impingement, edge-loading, and cup malpositioning. These risk factors are similar to those for generation of stripe wear. However, it is unclear whether the biomechanical conditions contributing to stripe wear generation also increase the risk for ceramic liner fracture

QUESTIONS/PURPOSES

We asked whether (1) head stripe wear propensity; and (2) cup orientation would correlate with alumina liner fracture risk for instances of normal and elevated body weight.

METHODS

An eXtended Finite Element Method (XFEM) model was developed to investigate these mechanisms. Liner fracture risk for 36-mm alumina bearings was studied by simulating two fracture-prone motions: stooping and squatting. Twenty-five distinct cup orientations were considered with variants of both acetabular inclination and anteversion. Four separate body mass indices were considered: normal (25 kg/m(2)) and three levels of obesity (33, 42, and 50 kg/m(2)). Material properties were modified to simulate alumina with and without the presence of dispersed microflaws. The model was validated by corroboration with two previously published ceramic liner fracture studies.

RESULTS

Of 200 XFEM simulations with flaw-free alumina, fracture occurred in eight instances, all of them involving obesity. Each of these occurred with cups in ≤ 37° inclination and in 0° anteversion. For 200 corresponding simulations with microflawed alumina, fracture propensity was greatest for cups with higher (edge loading-associated) scraping wear. Fracture risk was greatest for cups with lower inclination (average 42° for fractured cases versus 48° for nonfractured cases) and lower anteversion (9° versus 20°).

CONCLUSIONS

Fracture propensity for 36-mm liners was elevated for cups with decreased anteversion and/or inclination and under conditions of patient obesity.

CLINICAL RELEVANCE

Factors causing stripe wear, including obesity and cup malpositioning, also involve increased risk of ceramic liner fracture and merit heightened concern.