Patient-specific geometrical modeling of orthopedic structures with high efficiency and accuracy for finite element modeling and 3D printing

A novel personalized homogenous finite element model to predict the pull-out strength of cancellous bone screws

BACKGROUND

Orthopedic surgeries often involve the insertion of bone screws for various fixation systems. The risk of postoperative screw loosening is usually assessed through experimental or finite element (FE) evaluations of the screw pull-out strength. FE simulations are based on either personalized complex but accurate heterogeneous modeling or non-personalized simple but relatively less accurate homogeneous modeling. This study aimed to develop and validate a novel personalized computed tomography (CT)-based homogeneous FE simulation approach to predict the pull-out force of cancellous bone screws.

METHODS

Twenty FE simulations of L1-L5 vertebral screw pull-out tests were conducted, i.e., 10 heterogeneous and 10 homogenous models. Screws were inserted into the lower-middle region of vertebrae. In our novel homogeneous model, the region around approximately twice the diameter of the screw was used as a bone material reference volume. Subsequently, the overall material property of this region was homogeneously attributed to the entire vertebra, and pull-out simulations were conducted.

RESULTS

The mean error of the predicted pull-out forces by our novel homogenous simulations was ~ 7.9% with respect to our heterogeneous model. When solely the cancellous bone was involved during the pull-out process (i.e., for L1, L2, and L3 vertebral bodies whose cortical bone in the inferior region is thin), the novel homogenous model yielded small mean error of < 6.0%. This error, however, increased to ~ 11% when the screw got involved to the cortical bone (for L4 and L5 vertebrae whose cortical bone in the inferior region is thick).

CONCLUSION

The proposed personalized CT-based homogenous model was highly accurate in estimating the pull-out force especially when only the cancellous bone was involved with the screw.

Biomechanical evaluation of three implants for treating unstable femoral intertrochanteric fractures: finite element analysis in axial, bending and torsion loads

Purpose: How to effectively enhance the mechanical stability of intramedullary implants for unstable femoral intertrochanteric fractures (UFIFs) is challenging. The authors developed a new implant for managing such patients. Our aim was to enhance the whole mechanical stability of internal devices through increasing antirotation and medial support. We expected to reduce stress concentration in implants. Each implant was compared to proximal femoral nail antirotation (PFNA) via finite element method. Methods: Adult AO/OTA 31-A2.3 fracture models were constructed, and then the new intramedullary system (NIS), PFNA, InterTan nail models were assembled. We simulated three different kinds of load cases, including axial, bending, and torsion loads. For further comparison of PFNA and the NIS, finite element analysis (FEA) was repeated for five times under axial loads of 2100 N. Two types of displacement and stress distribution were assessed. Results: Findings showed that the NIS had the best mechanical stability under axial, bending, and torsion load conditions compared to PFNA and InterTan. It could be seen that the NIS displayed the best properties with respect to maximal displacement while PFNA showed the worst properties for the same parameter in axial loads of 2100 N. In terms of maximal stress, also the NIS exhibited the best properties while PFNA showed the worst properties in axial loads of 2100 N. For bending and torsion load cases, it displayed a similar trend with that of axial loads. Moreover, under axial loads of 2100 N, the difference between the PFNA group and the NIS group was statistically significant (p < 0.05). Conclusion: The new intramedullary system exhibited more uniform stress distribution and better biomechanical properties compared to the PFNA and InterTan. This might provide a new and efficacious device for managing unstable femoral intertrochanteric fractures.

Accuracy of 3D printed spine models for pre-surgical planning of complex adolescent idiopathic scoliosis (AIS) in spinal surgeries: a case series

Adolescent idiopathic scoliosis (AIS) is a noticeable spinal deformity in both adult and adolescent population. In majority of the cases, the gold standard of treatment is surgical intervention. Technological advancements in medical imaging and 3D printing have revolutionised the surgical planning and intraoperative decision making for surgeons in spinal surgery. However, its applicability for planning complex spinal surgeries is poorly documented with human subjects. The objective of this study is to evaluate the accuracy of 3D printed models for complex spinal deformities based on Cobb angles between 40° to 95°.This is a retrospective cohort study where, five CT scans of the patients with AIS were segmented and 3D printed for evaluating the accuracy. Consideration was given to the Inter-patient and acquisition apparatus variability of the CT-scan dataset to understand the effect on trueness and accuracy of the developed CAD models. The developed anatomical models were re-scanned for analysing quantitative surface deviation to assess the accuracy of 3D printed spinal models. Results show that the average of the root mean square error (RMSE) between the 3DP models and virtual models developed using CT scan of mean surface deviations for the five 3d printed models was found to be 0.5±0.07 mm. Based on the RMSE, it can be concluded that 3D printing based workflow is accurate enough to be used for presurgical planning for complex adolescent spinal deformities. Image acquisition and post processing parameters, type of 3D printing technology plays key role in acquiring required accuracy for surgical applications.

Exploring the value of three-dimensional printing and virtualization in paediatric healthcare: A multi-case quality improvement study

Background

Three-dimensional printing is being utilized in clinical medicine to support activities including surgical planning, education, and medical device fabrication. To better understand the impacts of this technology, a survey was implemented with radiologists, specialist physicians, and surgeons at a tertiary care hospital in Canada, examining multidimensional value and considerations for uptake.

Objectives

To examine how three-dimensional printing can be integrated into the paediatric context and highlight areas of impact and value to the healthcare system using Kirkpatrick's Model. Secondarily, to explore the perspective of clinicians utilizing three-dimensional models and how they make decisions about whether or not to use the technology in patient care.

Methods

A post-case survey. Descriptive statistics are provided for Likert-style questions, and a thematic analysis was conducted to identify common patterns in open-ended responses.

Results

In total, 37 respondents were surveyed across 19 clinical cases, providing their perspectives on model reaction, learning, behaviour, and results. We found surgeons and specialists to consider the models more beneficial than radiologists. Results further showed that the models were more helpful when used to assess the likelihood of success or failure of clinical management strategies, and for intraoperative orientation. We demonstrate that three-dimensional printed models could improve perioperative metrics, including a reduction in operating room time, but with a reciprocal effect on pre-procedural planning time. Clinicians who shared the models with patients and families thought it increased understanding of the disease and surgical procedure, and had no effect on their consultation time.

Conclusions

Three-dimensional printing and virtualization were used in preoperative planning and for communication among the clinical care team, trainees, patients, and families. Three-dimensional models provide multidimensional value to clinical teams, patients, and the health system. Further investigation is warranted to assess value in other clinical areas, across disciplines, and from a health economics and outcomes perspective.

Finite Element Analysis of Proximal Femur Bionic Nail (PFBN) Compared with Proximal Femoral Nail Antirotation and InterTan in Treatment of Intertrochanteric Fractures

Objective

To compare the biomechanical properties of proximal femur bionic nail (PFBN), proximal femoral nail antirotation (PFNA) and InterTan in the treatment of elderly intertrochanteric fractures AO/OTA 31‐A1.3 by finite element analysis.

Methods

We used Mimics, Unigraphics and other software to establish normal femur and AO/OTA 31‐A1.3 fracture models, and reconstructed PFBN, PFNA and InterTan intramedullary nail models, and assembled them on the fracture model. The ANSYS software was used to compare the femoral von Mises stress distribution, deformation distribution, and internal fixation stress distribution of each group under a load of 2100 N.

Results

It could be seen that the femoral maximum stress, femoral maximum displacement, and maximum stress of internal fixation of the PFBN group were lower than those in the PFNA group and the InterTan group. The maximum femoral stress of the PFBN was 190.25 MPa, while the maximum stress of the femur of the PFNA and InterTan groups were 238.41 Mpa and 226.97 Mpa. The maximum femoral displacement of each group were located at the top of the femoral head, and the maximum displacement of the PFBN group was 14.373 mm, and the maximum displacement values of the PFNA and InterTan groups were 19.49 and 15.225 mm. For the stress distribution of intramedullary nail, the maximum stress of the three kinds of internal fixation was located on the main nail. The maximum stress of PFBN was 1191.8 MPa, compared with 2142.8 MPa for PFNA and 1702.3 MPa for InterTan. And the maximum stress on the PFBN pressure nail was 345.35 MPa, compared with 868.6 MPa for the PFNA spiral blade and 545.5 MPa for InterTan interlocking twin nails.

Conclusion

Compared with PFNA and InterTan, PFBN has better mechanical properties. The biomechanical characteristics of PFBN are more advantageous than PFNA and InterTan internal fixation system in the treatment of femoral intertrochanteric fractures.

FINITE ELEMENT SPINE MODELS AND SPINAL INSTRUMENTS: A REVIEW

There is considerable biomechanics literature on finite element modeling and analysis of the spine. To accurately mimic the biomechanical behavior of the vertebral column, a generated computational model has to include anatomical structures that are consistent with physiological reality. In this review article, we focused on the finite element spine models that have been developed by various approaches in the literature. Firstly, the anatomical features of the spine and the spinal components have been briefly explained. We then focused on the modeling stages of vertebrae, ligaments, facet joints, intervertebral discs, and spinal instruments. With this paper, we expect to provide a comprehensive resource regarding the modeling preferences used in spine modeling.

Comparison of oblique triangular configuration and inverted equilateral triangular configuration of three cannulated screws in treating unstable femoral neck fracture: A finite element analysis

BACKGROUND

The cross-sectional area of three parallel screws might affect the stability of the internal fixation of femoral neck fractures. The screws fixed in the oblique-triangle configuration (OTC) were assumed to have a larger cross-sectional area, but the biomechanical stability has not yet been validated. In this study, finite element analyses were performed to compare the biomechanical properties of the internal fixation fixed by the OTC and the traditional Inverted Equilateral Triangle Configuration (IETC).

METHOD

Pauwels type III fracture was established on the three-dimensional femoral model and three cannulated screws with the OTC and traditional IETC methods were applied. The oblique-triangle configuration with the largest area inscribed the femoral neck isthmus by the three screws was determined, the area and circumference of the cross-section formed by the OTC and IETC model were compared. Stress, strain, and displacement peaks of the two configuration models under different loads were compared. Twelve pairs of nodes on the fracture ends were selected and the displacement of the fracture ends was evaluated through the displacement between these nodes.

RESULTS

The area and circumference of the cross-section formed by the OTC were larger than those in the IETC model. The degree of stress dispersion around the screw holes in the OTC model was better than that of the IETC, but the stress distribution order of the three screws in the two models was consistent. The maximum stress, strain, displacement, and displacement of the fracture end in the OTC model were smaller than those in the IETC model. The stress, strain, displacement, and fracture end displacement peaks of the two fixed models gradually increase with the increase of loads.

CONCLUSION

The oblique-triangle configuration showed superior mechanical properties than the IETC in finite element analyses. This study suggests that when three screws are fixed in parallel method, the larger the cross-sectional area of the screw configuration, the better stability of the internal fixation might be obtained. Furthermore, the biomechanical properties of various spatial configurations and screw holes of the three parallel screws need to be considered before clinical practice.

In Silico Optimization of Femoral Fixator Position and Configuration by Parametric CAD Model

Structural analysis, based on the finite element method, and structural optimization, can help surgery planning or decrease the probability of fixator failure during bone healing. Structural optimization implies the creation of many finite element model instances, usually built using a computer-aided design (CAD) model of the bone-fixator assembly. The three most important features of such CAD models are: parameterization, robustness and bidirectional associativity with finite elements (FE) models. Their significance increases with the increase in the complexity of the modeled fixator. The aim of this study was to define an automated procedure for the configuration and placement of fixators used in the treatment of long bone fractures. Automated and robust positioning of the selfdynamisable internal fixator on the femur was achieved and sensitivity analysis of fixator stress on the change of major design parameters was performed. The application of the proposed methodology is considered to be beneficial in the preparation of CAD models for automated structural optimization procedures used in long bone fixation.

The Future of Biomechanical Spine Research: Conception and Design of a Dynamic 3D Printed Cervical Myelography Phantom

Background

Three-dimensional (3D) printing is a growing practice in the medical community for patient care and trainee education as well as production of equipment and devices. The development of functional models to replicate physiologic systems of human tissue has also been explored, although to a lesser degree. Specifically, the design of 3D printed phantoms that possess comparable biomechanical properties to human cervical vertebrae is an underdeveloped area of spine research. In order to investigate the functional uses of cervical 3D printed models for replicating the complex physiologic and biomechanical properties of the human subaxial cervical spine, our institution has created a prototype that accurately reflects these properties and provides a novel method of assessing spinal canal dimensions using simulated myelography. To our knowledge, this is the first 3D printed phantom created to study these parameters.

Materials and methods

A de-identified cervical spine computed tomography imaging file was segmented using threshold modulation in 3D Slicer software. The subaxial vertebrae (C3-C7) of the scan were individualized by separating the facet joint spaces and uncovertebral joints within the software in order to create individual stereolithography (STL) files. Each individual vertebra was printed on an Ultimaker S5 dual-extrusion printer using white “tough” polylactic acid filament. A human cadaveric subaxial cervical spine was harvested to provide a control for our experiment. Both models were assessed and compared in flexion and extension dynamic motion grossly and fluoroscopically. The maximum angles of deformation on X-ray imaging were recorded using DICOM (Digital Imaging and Communications in Medicine) viewing software. In order to compare the ability to assess canal dimensions of the models using fluoroscopic imaging, a myelography simulation was designed.

Results

The cervical phantom demonstrated excellent ability to resist deformation in flexion and extension positions, attributed to the high quality of initial segmentation. The gross and fluoroscopic dynamic movement of the phantom was analogous to the cadaver model. The myelography simulator adequately demonstrated the canal dimensions in static and dynamic positions for both models. Pertinent anatomic landmarks were able to be effectively visualized for assessment of canal measurements for sagittal and transverse dimensions.

Conclusions

By utilizing the latest technologies in DICOM segmentation and 3D printing, our institution has created the first cervical myelography phantom for biomechanical evaluation and trainee instruction. By combining new technologies with anatomical knowledge, quality 3D printing shows great promise in becoming a standard player in the future of spinal biomechanical research.

[Kinematic examination of the musculoskeletal system : Use of methods of image and image sequence analyses as well as shape and motion models]

Image-based preoperative planning has become a routine component in surgery on the musculoskeletal system. In joint arthroplasty it is obligatory. Surgeons are increasingly considering new approaches with additional computer-based kinematic examinations that also generate dynamic image analyses. This article describes several of these new examination techniques and discusses their clinical relevance.