Second-generation locking mechanisms and ethylene oxide sterilization reduce tibial insert backside damage in total knee arthroplasty

A Polished Cobalt-Chrome Baseplate is not Associated With a Lower Revision Rate Than Matt Titanium in a Single Total Knee Arthroplasty Implant System With Identical Baseplate Design

BACKGROUND

Polished baseplates were introduced into total knee arthroplasty (TKA) systems to reduce the incidence of backside wear. In 2004, a fixed-bearing knee arthroplasty system underwent a change in baseplate material from matt titanium to polished cobalt-chrome (CoCr) with the intention to reduce backside wear. Other design aspects were left unchanged. The aim of this study was to compare these implants with each baseplate using data from the Australian Orthopaedic Association National Joint Replacement Registry.

METHODS

Primary TKA procedures performed between January 2010 and December 2021 for osteoarthritis, using a single design with cross-linked polyethylene inserts and matt titanium or polished CoCr baseplates, were analyzed. The primary outcome was all-cause revision, summarized using Kaplan-Meier estimates, with age- and sex-adjusted hazard ratios estimated from Cox proportional hazards models. In total, there were 2,091 procedures with matt titanium and 2,519 procedures with polished CoCr baseplates.

RESULTS

The 9-year cumulative percent revision was 2.5% (95% confidence interval [CI] 1.8 to 3.5%) and 4.2% (95% CI 3.1 to 5.6%) for the matt titanium and CoCr groups, respectively. Compared to matt titanium, the revision rate of CoCr baseplates was not significantly higher (hazard ratio 1.44; 95% CI 0.96 to 2.15; P = .076).

CONCLUSIONS

Polished CoCr baseplates in a single TKA system were not associated with reduced all-cause revision rates compared to matt titanium up to 11 years post-TKA. Our results suggest that the predicted reduction in wear particle debris production from polished CoCr baseplates may not correlate with reduced revision rates in vivo, but further evaluation is required.

Computational wear of knee implant polyethylene insert surface under continuous dynamic loading and posterior tibial slope variation based on cadaver experiments with comparative verification

Background

The effect of posterior tibial slope on the maximum contact pressure and wear volume of polyethylene (PE) insert were not given special attention. The effects of flexion angle, Anterior-Posterior (AP) Translation, and Tibial slope on the max contact pressure and wear of PE insert of TKR were investigated under loadings which were obtained in cadaver experiments by using Archard’s wear law. This study uses not only loads obtained from cadaver experiments but also dynamic flexion starting from 0 to 90 degrees.

Method

Wear on knee implant PE insert was investigated using a 2.5 size 3 dimensional (3D) cruciate sacrificing total knee replacement model and Finite Element Method (FEM) under loadings and AP Translation data ranging from 0 to 90 flexion angles validated by cadaver experiments. Two types of analyses were done to measure the wear effect on knee implant PE insert. The first set of analyses included the flexion angles dynamically changing with the knee rotating from 0 to 90 angles according to the femur axis and the transient analyses for loadings changing with a certain angle and duration.

Results

It is seen that the contact pressure on the PE insert decreases as the cycle increases for both Flexion and Flexion+AP Translation. It is clear that as the cycle increases, the wear obtained for both cases increases. The loadings acting on the PE insert cannot create sufficient pressure due to the AP Translation effect at low speeds and have an effect to reduce the wear, while the effect increases with the wear as the cycle increases, and the AP Translation now contributes to the wear at high speeds. It is seen that as the posterior tibial slope angle increases, the maximum contact pressure values slightly decrease for the same cycle.

Conclusions

This study indicated that AP Translation, which changes direction during flexion, had a significant effect on both contact pressure and wear. Unlike previous similar studies, it was seen that the amount of wear continues to increase as the cycle increases. This situation strengthens the argument that loading and AP Translation values that change with flexion shape the wear effects on PE Insert.

Tibial tray debonding from the cement mantle is associated with deformation of the backside of polyethylene tibial inserts

AIMS

The aim of this study was to investigate whether wear and backside deformation of polyethylene (PE) tibial inserts may influence the cement cover of tibial trays of explanted total knee arthroplasties (TKAs).

METHODS

At our retrieval centre, we measured changes in the wear and deformation of PE inserts using coordinate measuring machines and light microscopy. The amount of cement cover on the backside of tibial trays was quantified as a percentage of the total surface. The study involved data from the explanted fixed-bearing components of four widely used contemporary designs of TKA (Attune, NexGen, Press Fit Condylar (PFC), and Triathlon), revised for any indication, and we compared them with components that used previous generations of PE. Regression modelling was used to identify variables related to the amount of cement cover on the retrieved trays.

RESULTS

A total of 114 explanted fixed-bearing TKAs were examined. This included 76 used with contemporary PE inserts which were compared with 15 used with older generation PEs. The Attune and NexGen (central locking) trays were found to have significantly less cement cover than Triathlon and PFC trays (peripheral locking group) (p = 0.001). The median planicity values of the PE inserts used with central locking trays were significantly greater than of those with peripheral locking inserts (205 vs 85 microns; p < 0.001). Attune and NexGen inserts had a characteristic pattern of backside deformation, with the outer edges of the PE deviating inferiorly, leaving the PE margins as the primary areas of articulation.

CONCLUSION

Explanted TKAs with central locking mechanisms were significantly more likely to debond from the cement mantle. The PE inserts of these designs showed characteristic patterns of deformation, which appeared to relate to the manufacturing process and may be exacerbated in vivo. This pattern of deformation was associated with PE wear occurring at the outer edges of the articulation, potentially increasing the frictional torque generated at this interface. Cite this article: Bone Joint J 2021;103-B(12):1791-1801.

Current Total Knee Designs: Does Baseplate Roughness or Locking Mechanism Design Affect Polyethylene Backside Wear?

BACKGROUND

Tibial baseplate roughness and polyethylene-insert micromotion resulting from locking-mechanism loosening can lead to polyethylene backside wear in TKAs. However, many retrieval studies examining these variables have evaluated only older TKA implant designs.

QUESTIONS

We used implant-retrieval analysis to examine if there were differences in: (1) backside damage scores, (2) backside damage modes, and (3) backside linear wear rates in five TKA implant designs owing to differing baseplate surface roughness and locking mechanisms. Additionally, we examined if (4) patient demographics influence backside damage and wear.

METHODS

Five TKA implant models (four modern and one historical design) were selected with different tibial baseplate and/or locking mechanism designs. Six tibial inserts retrieved at the time of revision from each TKA model were matched for time in vivo, age of the patient at TKA revision, BMI, sex, revision number, and revision reason. Each insert backside was analyzed for: (1) visual total damage score and (2) individual visual damage modes, both by two observers and with an intraclass correlation coefficient of 0.66 (95% CI, 0.39-0.92), and (3) linear wear rate measured by micro-CT. Median primary outcomes were compared among the five designs. For our given sample size among five groups we could detect with 80% power a 10-point difference in damage score and an 0.11-mm per year difference in wear rate.

RESULTS

The polished tibial design with a partial peripheral capture locking mechanism and anterior constraint showed a lower total damage score compared with the nonpolished tibial design with only a complete peripheral-rim locking mechanism (median, 12.5; range, 9.5-18.0; 95% CI, 9.58-16.42 versus median, 22.3; range, 15.5-27.0; 95% CI, 17.5-26.5; p = 0.019). The polished baseplate with a tongue-in-groove locking mechanism showed more abrasions than the nonpolished baseplate with a peripheral-rim capture and antirotational island (median, 7.25; range, 0.5-8.0; 95% CI, 2.67-8.99 versus median, 0.75; range, 0-1.5; 95% CI, 0.20-1.47; p = 0.016)). Dimpling was a unique wear mode to the nonpolished baseplates with the peripheral-rim capture and antirotational island (median, 5.5; range, 2.0-9.0; 95% CI, 2.96-8.38) and the peripheral-rim capture alone (median, 9.0; range, 6.0-10.0; 95% CI, 7.29-10.38). Overall, the linear wear rate for polished designs was lower than for nonpolished designs (0.0102 ± 0.0044 mm/year versus 0.0224 ± 0.0119 mm/year; p < 0.001). Two of the polished baseplate designs, the partial peripheral capture with anterior constraint (median, 0.083 mm/year; range, 0.0037-0.0111 mm/year; 95% CI, 0.0050-0.0107 mm versus median, 0.0245 mm/year; range, 0.014-0.046 mm/year; 95% CI, 0.0130-0.0414 mm; p = 0.008) and the tongue-in-groove locking mechanism (median, 0.0085 mm/year; range, 0.005-0.015 mm/year; 95% CI, 0.0045-0.0138 mm; p = 0.032) showed lower polyethylene linear wear rates compared with the nonpolished baseplate design with only a peripheral-rim capture.

CONCLUSIONS

Total damage scores and linear wear rates were highest involving the nonpolished design with only a peripheral rim capture. There were no differences among the other TKA designs regarding damage and wear, but this finding should be considered in the setting of a relatively small sample size.

CLINICAL RELEVANCE

Our study showed that in the complex interplay between baseplate surface finish and locking mechanism design, a polished baseplate with a robust locking mechanism had the lowest backside damage and linear wear. However, improvements in locking mechanism design in nonpolished baseplates potentially may offset some advantages of a polished baseplate. Further retrieval analyses need to be done to confirm such findings, especially analyzing current crosslinked polyethylene. Additionally, we need mid- and long-term studies comparing TKA revisions attributable to wear and osteolysis among implants before understanding if such design differences are clinically relevant.

A Novel Percentage-Based System for Determining Aseptic Loosening of Total Knee Arthroplasty Tibial Components

BACKGROUND

There are limited data on evaluating the significance of radiolucent lines and aseptic loosening in total knee arthroplasty (TKA). We sought to compare the sensitivity, specificity, and reliability of the Knee Society Total Knee Arthroplasty Roentgenographic Evaluation and Scoring System (KSRES) in detecting tibial component loosening compared to a novel percentage-based system (PBS).

METHODS

We retrospectively reviewed radiographs obtained from 48 patients within 6 months prior to revision TKA. The radiographs were randomized and four reviewers independently used the KSRES to categorize tibial implants as nonconcerning, clinical follow-up for progression, or loose as described by KSRES. For the PBS, the percent involvement of the tibial implant interface of any radiolucency at the bone-cement or cement-implant interface was determined. The higher percentage from either the anteroposterior or the lateral image was the final score. Components were categorized as nonconcerning (≤10%), clinical follow-up for progression (11%-24%), or loose (≥25%). We compared the sensitivity, specificity, and interobserver reliability using intraoperative assessment of implant fixation as the gold standard.

RESULTS

For the KSRES, the mean sensitivity for determining tibial loosening was 7.3% and mean specificity for determining a nonconcerning implant was 95.9%. The PBS significantly increased the sensitivity to 91.1% (P < .001) while maintaining a specificity of 87.9% (P = .2). Interobserver reliability significantly increased from a mean kappa of 0.26 to 0.75 (P < .001).

CONCLUSION

The KSRES significantly underestimates implant loosening. The proposed percentage-based system demonstrated excellent sensitivity, specificity, and interobserver reliability in determining tibial implant loosening in this patient population.

Peripheral snap-fit locking mechanisms and smooth surface finish of tibial trays reduce backside wear in fixed-bearing total knee arthroplasty

Background and purpose - Severe backside wear, observed in older generations of total knee replacements (TKRs), led to redesign of locking mechanisms to reduce micromotions between tibial tray and inlay. Since little is known about whether this effectively reduces backside wear in modern designs, we examined backside damage in retrievals of various contemporary fixed-bearing TKRs. Patients and methods - A consecutive series of 102 inlays with a peripheral (Stryker Triathlon, Stryker Scorpio, DePuy PFC Sigma, Aesculap Search Evolution) or dovetail locking mechanism (Zimmer NexGen, Smith and Nephew Genesis II) was examined. Articular and backside surface damage was evaluated using the semiquantitative Hood scale. Inlays were examined using scanning electron microscopy (SEM) to determine backside wear mechanisms. Results - Mean Hood scores for articular (A) and backside (B) surfaces were similar in most implants-Triathlon (A: 46, B: 22), Genesis II (A: 55, B: 24), Scorpio (A: 57, B: 24), PFC (A: 52, B: 20); Search (A: 56, B: 24)-except the NexGen knee (A: 57, B: 60), which had statistically significantly higher backside wear scores. SEM studies showed backside damage caused by abrasion related to micromotion in designs with dovetail locking mechanisms, especially in the unpolished NexGen trays. In implants with peripheral liner locking mechanism, there were no signs of micromotion or abrasion. Instead, "tray transfer" of polyethylene and flattening of machining was observed. Interpretation - Although this retrieval study may not represent well-functioning TKRs, we found that a smooth surface finish and a peripheral locking mechanism reduce backside wear in vivo, but further studies are required to determine whether this actually leads to reduced osteolysis and lower failure rates.

Towards an understanding of the painful total knee: what is the role of patient biology?

Total knee arthroplasty (TKA) remains the treatment of choice for end-stage osteoarthritis of the knee. With an aging population, the demand for TKA continues to increase, placing a significant burden on a health care system that must function with limited resources. Although generally accepted as a successful procedure, 15-30 % of patients report persistent pain following TKA. Classically, pain generators have been divided into intra-articular and extra-articular causes. However, there remains a significant subset of patients for whom pain remains unexplained. Recent studies have questioned the role of biology (inflammation) in the persistence of pain following TKA. This article aims to serve as a review of previously identified causes of knee pain following TKA, as well as to explore the potential role of biology as a predictor of pain following knee replacement surgery.

Changes in surface topography at the TKA backside articulation following in vivo service: a retrieval analysis

PURPOSE

With the advent of modular total knee arthroplasty (TKA) systems, backside wear at the articulation between the ultra-high-molecular-weight-polyethylene (UHMWPE) component undersurface and the tibial baseplate has received increasing attention as a source of clinically significant polyethylene wear debris. The aim of this study was to investigate the reciprocating interface at the TKA undersurface articulation using profilometry after in vivo service. Our null hypothesis was that there would be no discernible pattern or relationship between the metal tibial baseplate and UHMWPE surface profile.

METHODS

A nanoscale analysis of thirty retrieved fixed-bearing TKA explants was performed. Surface roughness (Sa) and skewness (Ssk) were measured on both the UHMWPE component undersurface and the tibial baseplate of explants using a non-contacting profilometer (1 nm resolution). Four pristine unimplanted components of two different designs (Stryker Kinemax and DePuy PFC) were examined for control purposes.

RESULTS

Mean explant baseplate surface roughness was 1.24 μm (0.04-3.01 μm). Mean explant UHMWPE undersurface roughness was 1.16 μm (0.23-2.44 μm). Each explant had an individual roughness pattern with unique baseplate and undersurface UHMWPE surface roughness that was different from, but closely related to, surface topography observed in control implants of the same manufacturer and design. Following in vivo service, UHMWPE undersurface showed changes towards a negative skewness, demonstrating that wear is occurring at the backside interface.

CONCLUSION

In vivo loading of the TKA prosthesis leads to measurable changes in surface profile at the backside articulation, which appear to be dependent on several factors including implant design and in vivo duration. These findings are consistent with wear occurring at this surface. Findings of this study would support the use of a polished tibial tray over an unpolished design in total knee arthroplasty with the goal of reducing PE wear by means of providing a smoother backside countersurface for the UHMWPE component.

Contribution of Surface Polishing and Sterilization Method to Backside Wear in Total Knee Arthroplasty

The purpose of this study was to compare the relative contributions of backside wear from polished and roughened tibial baseplates and different sterilization methods. Three groups of tibial inserts of the same design were matched: roughened gamma-air (RGA), polished gamma-air (PGA), and polished gas-plasma (PGP). Visual damage scoring and micro-CT deviation maps were used for evaluation. Total backside damage was higher (P=0.045) in RGA (13.8±3.4) compared to PGA (8.7±3.4) and PGP (8.2±4.8). Backside wear rates were greatest (P=0.02) in RGA (0.038 mm/year), followed by PGA (0.012 mm/year), and lowest in PGP (0.009 mm/year). Use of a roughened tibial baseplate had a greater effect on wear magnitude than sterilization method.

Wear and creep behavior of total knee implants undergoing wear testing

We sought to determine what dimensional changes occurred from wear testing of a total knee implant, as well as any changes within the polyethylene subsurface. Three fixed bearing implants underwent wear simulator testing to 6.1 million cycles. Gravimetric analysis and micro-CT scans were performed pre-test, mid-test, and post-test. Wear volume and surface deviations were greater during 0-3.2 million cycles (91 ± 12mm(3)) than from 3.2 to 6.1 million cycles (52 ± 18mm(3)). Deviations (wear and creep) occurred across all surfaces of the tibial inserts, including the articular surface, backside surface, sides, and locking mechanism. No subsurface changes were found. The micro-CT results were a useful adjunct to gravimetric analysis, defining the dimensional changes that occurred with testing and ruling out subsurface fatigue.

Why are total knees failing today? Etiology of total knee revision in 2010 and 2011

Revision knee data from six joint arthroplasty centers were compiled for 2010 and 2011 to determine mechanism of failure and time to failure. Aseptic loosening was the predominant mechanism of failure (31.2%), followed by instability (18.7%), infection (16.2%), polyethylene wear (10.0%), arthrofibrosis (6.9%), and malalignment (6.6%). Mean time to failure was 5.9 years (range 10 days to 31 years). 35.3% of all revisions occurred less than 2 years after the index arthroplasty, 60.2% in the first 5 years. In contrast to previous reports, polyethylene wear is not a leading failure mechanism and rarely presents before 15 years. Implant performance is not a predominant factor of knee failure. Early failure mechanisms are primarily surgeon-dependent.

Prediction of backside micromotion in total knee replacements by finite element simulation

The micromotion at the interface between the polyethylene tibial insert and metal tibial tray [corrected] in modular total knee replacements [corrected] has been shown to contribute to wear particle-induced osteolysis and may [corrected] cause implant failure. Therefore, studying the design parameters that are involved in the backside wear process is an important task that may lead to improvement in new total knee replacements. In the present study, a finite element model was developed to predict the backside micromotion along the entire modular interface. Both the linear elastic constitutive model and non-linear J2-plasticity constitutive model were considered in the finite element model for polyethylene and were corroborated against published results obtained from displacement controlled knee simulator wear tests. The finite element simulation with the non-linear J2-plasticity constitutive model was able to predict backside micromotion [corrected] more accurately than the simulation with the linear elastic constitutive model. [corrected] The developed finite element model (including the non-linear J2-plasticity constitutive model) was then applied to assess the effects of the tibial tray locking mechanism design (dovetails versus fullperipheral [corrected] design) and different levels of interference fit on insert micromotion. The developed finite element model, implementing the non-linear J2-plasticity constitutive model, was shown to successfully predict clinical amounts of backside micromotion and could be used for the design and development of total knee replacements for the reduction of backside micromotion and polyethylene [corrected] wear.