Biomechanical investigation into the structural design of porous additive manufactured cages using numerical and experimental approaches

Finite element modelling and biodynamic response prediction of the seated human body exposed to whole-body vibration

Biodynamic modelling of seat-occupant systems can assist in seat comfort design. A finite element (FE) model of the seated human body, including detailed modelling of the lumbar spine, was established to reflect the human response to vibration and biodynamic response of the lumbar spine under whole-body vibration (WBV). The lumbar spine model was established and validated against the in-vitro results and calculated data. The posture of the lumbar spine was adjusted according to the radiological research results, and the adjusted model was combined to establish a FE model of the seated human body. The present seated human model with backrest inclination angles of 10, 20, and 30°, validated by comparing the measured apparent mass and seat-to-lumbar spine transmissibility, was used to calculate the biodynamic response of the lumbar spine with three inclined backrests under WBV. The results showed that the model could characterise the apparent mass, seat-to-lumbar spine transmissibility, and the biodynamic response of the lumbar spine. Practitioner summary: Biodynamic models can represent dynamic characteristics of the human body exposed to vibration and assist in seat comfort design. The three-dimensional FE model of the human body can be used to explore the human response to vibration and the biodynamic response of the lumbar spine under WBV.

3D printing for spine pathologies: a state-of-the-art review

Three-Dimensional Printing has advanced throughout the years in the field of biomedical science with applications, especially in spine surgeries. 3D printing has the ability of fabricating highly complex structures with ease and high dimensional accuracy. The complexity of the spine's architecture and the inherent dangers of spinal surgery bring the evaluation of 3D printed models into consideration. This article summarizes the benefits of 3D printing based models for application in spine pathology. 3D printing technique is extensively used for fabrication of anatomical models, surgical guides and patient specific implants (PSI). The 3D printing based anatomical models assist in preoperative planning and training of students. Furthermore, 3D printed models can be used for improved communication and understanding of patients about the spinal disorders. The use of 3D printed surgical guides help in the stabilization of the spine during surgery, improving post procedural outcomes. Improved surgical results can be achieved by using PSIs that are tailored for patient specific needs. Finally, this review discusses the limitations and potential future scope of 3D printing in spine pathologies. 3D printing is still in its infancy, and further research would provide better understanding of the technology's true potential in spinal procedures.

Biomechanical analysis of functionally graded porous interbody cage for lumbar spinal fusion

Functionally graded porous (FGP) interbody cage might offer a trade-off between porosity-based reduction of stiffness and mechanical properties. Using finite element models of intact and implanted lumbar functional spinal unit (FSU), the study investigated the quantitative deviations in load transfer and adaptive changes in bone density distributions around FGP interbody cages. The cage had three graded porosities: FGP-A, -B, and -C corresponded to a maximum porosity levels of 48%, 65% and 78%, respectively. Efficacy of the FGP cages were evaluated by comparing the numerically predicted results of solid-Ti and uniformly porous 78% porosity (P78) cage. Variations in stiffness and interface condition affected the strain distribution and bone remodelling around the cages. Peak strains of 0.5-1% were observed in less number of peri-prosthetic bone elements for the FGP cages as compared to the solid-Ti cage. Strains and bone apposition were considerably higher for the bonded implant-bone interface condition than the debonded case. For the FGP-C with bonded interface condition, bone apposition of 11-20% was predicted in the L4 and L5 regions of interest (ROIs); whereas the debonded model exhibited 6-10% increase in bone density. The deviations in bone density change between FGP-C and P78 model were 3-8% for L4 and L5 ROIs. FGP resulted in a reduced average micromotion (∼70-106 μm) as compared to solid-Ti (116 μm), for all physiologic movements. Compared to solid-Ti and uniformly porous cages, the FGP cage seems to be a viable alternative considering the conflicting nature of strength and porosity.

An overview of 3D printed metal implants in orthopedic applications: Present and future perspectives

With the ability to produce components with complex and precise structures, additive manufacturing or 3D printing techniques are now widely applied in both industry and consumer markets. The emergence of tissue engineering has facilitated the application of 3D printing in the field of biomedical implants. 3D printed implants with proper structural design can not only eliminate the stress shielding effect but also improve in vivo biocompatibility and functionality. By combining medical images derived from technologies such as X-ray scanning, CT, MRI, or ultrasonic scanning, 3D printing can be used to create patient-specific implants with almost the same anatomical structures as the injured tissues. Numerous clinical trials have already been conducted with customized implants. However, the limited availability of raw materials for printing and a lack of guidance from related regulations or laws may impede the development of 3D printing in medical implants. This review provides information on the current state of 3D printing techniques in orthopedic implant applications. The current challenges and future perspectives are also included.

Effect of Interbody Implants on the Biomechanical Behavior of Lateral Lumbar Interbody Fusion: A Finite Element Study

Porous titanium interbody scaffolds are growing in popularity due to their appealing advantages for bone ingrowth. This study aimed to investigate the biomechanical effects of scaffold materials in both normal and osteoporotic lumbar spines using a finite element (FE) model. Four scaffold materials were compared: Ti6Al4V (Ti), PEEK, porous titanium of 65% porosity (P65), and porous titanium of 80% porosity (P80). In addition, the range of motion (ROM), endplate stress, scaffold stress, and pedicle screw stress were calculated and compared. The results showed that the ROM decreased by more than 96% after surgery, and the solid Ti scaffold provided the lowest ROM (1.2-3.4% of the intact case) at the surgical segment among all models. Compared to solid Ti, PEEK decreased the scaffold stress by 53-66 and the endplate stress by 0-33%, while porous Ti decreased the scaffold stress by 20-32% and the endplate stress by 0-32%. Further, compared with P65, P80 slightly increased the ROM (<0.03°) and pedicle screw stress (<4%) and decreased the endplate stress by 0-13% and scaffold stress by approximately 18%. Moreover, the osteoporotic lumbar spine provided higher ROMs, endplate stresses, scaffold stresses, and pedicle screw stresses in all motion modes. The porous Ti scaffolds may offer an alternative for lateral lumbar interbody fusion.

Mechanical Properties of AISI 316L Lattice Structures via Laser Powder Bed Fusion as a Function of Unit Cell Features

The growth of additive manufacturing processes has enabled the production of complex and smart structures. These fabrication techniques have led research efforts to focus on the application of cellular materials, which are known for their thermal and mechanical benefits. Herein, we studied the mechanical behavior of stainless-steel (AISI 316L) lattice structures both experimentally and computationally. The lattice architectures were body-centered cubic, hexagonal vertex centroid, and tetrahedron in two cell sizes and at two different rotation angles. A preliminary computational study assessed the deformation behavior of porous cylindrical samples under compression. After the simulation results, selected samples were manufactured via laser powder bed fusion. The results showed the effects of the pore architecture, unit cell size, and orientation on the reduction in the mechanical properties. The relative densities between 23% and 69% showed a decrease in the bulk material stiffness up to 93%. Furthermore, the different rotation angles resulted in a similar porosity level but different stiffnesses. The simulation analysis and experimental results indicate that the variation in the strut position with respect to the force affected the deformation mechanism. The tetrahedron unit cell showed the smallest variation in the elastic modulus and off-axis displacements due to the cell orientation. This study collected computational and experimental data for tuning the mechanical properties of lattice structures by changing the geometry, size, and orientation of the unit cell.

Recent advancement in finite element analysis of spinal interbody cages: A review

Finite element analysis (FEA) is a widely used tool in a variety of industries and research endeavors. With its application to spine biomechanics, FEA has contributed to a better understanding of the spine, its components, and its behavior in physiological and pathological conditions, as well as assisting in the design and application of spinal instrumentation, particularly spinal interbody cages (ICs). IC is a highly effective instrumentation for achieving spinal fusion that has been used to treat a variety of spinal disorders, including degenerative disc disease, trauma, tumor reconstruction, and scoliosis. The application of FEA lets new designs be thoroughly "tested" before a cage is even manufactured, allowing bio-mechanical responses and spinal fusion processes that cannot easily be experimented upon in vivo to be examined and "diagnosis" to be performed, which is an important addition to clinical and in vitro experimental studies. This paper reviews the recent progress of FEA in spinal ICs over the last six years. It demonstrates how modeling can aid in evaluating the biomechanical response of cage materials, cage design, and fixation devices, understanding bone formation mechanisms, comparing the benefits of various fusion techniques, and investigating the impact of pathological structures. It also summarizes the various limitations brought about by modeling simplification and looks forward to the significant advancement of spine FEA research as computing efficiency and software capabilities increase. In conclusion, in such a fast-paced field, the FEA is critical for spinal IC studies. It helps in quantitatively and visually demonstrating the cage characteristics after implanting, lowering surgeons' learning costs for new cage products, and probably assisting them in determining the best IC for patients.

Biomechanical role of cement augmentation in the vibration characteristics of the osteoporotic lumbar spine after lumbar interbody fusion

Under whole body vibration, how the cement augmentation affects the vibration characteristic of the osteoporotic fusion lumbar spine, complications, and fusion outcomes is unclear. A L1-L5 lumbar spine finite element model was developed to simulate a transforaminal lumbar interbody fusion (TLIF) model with bilateral pedicle screws at L4-L5 level, a polymethylmethacrylate (PMMA) cement-augmented TLIF model (TLIF-PMMA) and an osteoporotic TLIF model. A 40 N sinusoidal vertical load at 5 Hz and a 400 N preload were utilized to simulate a vertical vibration of the human body and the physiological compression caused by muscle contraction and the weight of human body. The results showed that PMMA cement augmentation may produce a stiffer pedicle screw/rod construct and decrease the risk of adjacent segment disease, subsidence, and rod failure under whole-body vibration(WBV). Cement augmentation might restore the disc height and segmental lordosis and decrease the risk of poor outcomes, but it might also increase the risk of cage failure and prolong the period of lumbar fusion under WBV. The findings may provide new insights for performing lumbar interbody fusion in patients affected by osteoporosis of the lumbar spine. Graphical abstract.

In Vitro and In Vivo Comparison of Bone Growth Characteristics in Additive-Manufactured Porous Titanium, Nonporous Titanium, and Porous Tantalum Interbody Cages

Autogenous bone grafts are the gold standard for interbody fusion implant materials; however, they have several disadvantages. Tantalum (Ta) and titanium (Ti) are ideal materials for interbody cages because of their biocompatibility, particularly when they are incorporated into a three-dimensional (3D) porous structure. We conducted an in vitro investigation of the cell attachment and osteogenic markers of self-fabricated uniform porous Ti (20%, 40%, 60%, and 80%), nonporous Ti, and porous Ta cages (n = 6) in each group. Cell attachment, osteogenic markers, and alkaline phosphatase (ALP) were measured. An in vivo study was performed using a pig-posterior-instrumented anterior interbody fusion model to compare the porous Ti (60%), nonporous Ti, and porous Ta interbody cages in 12 pigs. Implant migration and subsidence, determined using plain radiographs, were recorded before surgery, immediately after surgery, and at 1, 3, and 6 months after surgery. Harvested implants were assessed for bone ingrowth and attachment. Relative to the 20% and 40% porous Ti cages, the 60% and 80% cages achieved superior cellular migration into cage pores. Among the cages, osteogenic marker and ALP activity levels were the highest in the 60% porous Ti cage, osteocalcin expression was the highest in the nonporous Ti cage, and the 60% porous Ti cage exhibited the lowest subsidence. In conclusion, the designed porous Ti cage is biocompatible and suitable for lumbar interbody fusion surgery and exhibits faster fusion with less subsidence compared with porous Ta and nonporous Ti cages.

Bone Remodelling Around Solid and Porous Interbody Cages in the Lumbar Spine

Spinal fusion is an effective surgical treatment for intervertebral disc degeneration. However, the consequences of implantation with interbody cages on load transfer and bone remodelling in the vertebral bodies has scarcely been investigated. Using detailed 3D models of an intact and implanted lumbar spine and the strain energy density based bone remodelling algorithm, this study investigated the evolutionary changes in bone density distributions around porous and solid interbody cages. Follower load technique and submodelling approach were employed to simulate applied loading conditions on the lumbar spine models. The study determined the relationship between mechanical properties and parametrical characteristics of porous Body-centered-cubic (BCC) models, which corroborated well with Gibson-Ashby and exponential regression models. Variations in porosity affected the peri-prosthetic stress distributions and bone remodelling around the cages. In comparison to the solid cage, stresses and strains in the cancellous bone decreased with an increase in cage porosity; whereas the range of motion increased. For the solid cage, increase in bone density of 20-28% was predicted in the L4 inferior and L5 superior regions; whereas the model with 78% porosity exhibited a small 3-5% change in bone density. An overall increase of 9-14% bone density was predicted in the L4 and L5 vertebrae after remodelling for solid interbody cages, which may influence disc degeneration in the adjacent segment. In comparison to the solid cage, an interbody cage with 65-78% porosity could be a viable and promising alternative, provided sufficient mechanical strength is offered.

Static and Fatigue Load Bearing Investigation on Porous Structure Titanium Additively Manufactured Anterior Cervical Cages

This study investigates the static and fatigue behavior of porous and conventional anterior cervical cages. Porous structure titanium anterior cervical cages were manufactured using direct selective laser sintering technique. Four different types of cervical cages were designed and manufactured, among which three designs consist of porous structure (type 1, type 2, and type 3) and manufactured using metal 3D printing. Remaining one design (type 4) was manufactured using conventional machining and did not consist any porous structure. All types of manufactured cages were tested in compression under static and fatigue loading conditions as per ASTM F2077 standard. Static and fatigue subsidence testing was performed using ASTM F2267 standard. Static compression testing results of type 1 and type 4 cages reported higher yield load when compared to the type 2 and type 3 cages. Static subsidence testing results reported almost 11% less subsidence rate for additively manufactured cages than the conventional cages. Fatigue subsidence testing results showed that type 2 and type 3 cages can withstood approximately 21% higher number of cycles before subsidence as compare to the type 1 and type 4 cages. During fatigue testing, all the cages design survived 5 million cycles at the 3000 N loading. For 6000 N and 8000 N, loading rate type 2 and type 3 cages showed lower fatigue life when compared to other cages design. Since fatigue life of type 2 and type 3 cage designs were reported lower than other cages design, it is concluded that the performance of the additively manufactured porous cages can be significantly varied based upon the cage design features.

Biomechanical Evaluation of an Oblique Lateral Locking Plate System for Oblique Lumbar Interbody Fusion: A Finite Element Analysis

OBJECTIVE

The oblique lateral locking plate system (OLLPS) is a novel internal fixation with a locking and reverse pedicle track screw configuration designed for oblique lumbar interbody fusion (OLIF). The OLLPS is placed in a single position through the oblique lateral surgical corridor to reduce operative time and complications associated with prolonged anesthesia and prone positioning. The purpose of this study was to verify the biomechanical effect of the OLLPS.

METHODS

An intact finite element model of L1-S1 (intact) was established based on computed tomography images of a healthy male volunteer. The L4-L5 intervertebral space was selected as the surgical segment. The surgical models were established separately based on OLIF surgical procedures and different internal fixations: 1) stand-alone OLIF (SA); 2) OLIF with a 2-screw lateral plate; 3) OLIF with a 4-screw lateral plate; 4) OLIF with OLLPS; and 5) OLIF with bilateral pedicle screw fixation (BPS). After validation of the intact model, physiologic loads were applied to the superior surface of L1 to simulate motions such as flexion, extension, left bending, right bending, left rotation, and right rotation. The evaluation indices included the L4/5 range of motion, the L4 maximum displacement, and the maximum stresses of the superior and inferior end plates, the cage, and the supplemental fixation.

RESULTS

During OLIF surgery, the OLLPS provided multiplanar stability similar to that provided by BPS. Compared with 2-screw lateral plate and 4-screw lateral plate, OLLPS had better biomechanical properties in terms of enhancing the instant stability of the surgical segment, reducing the stress on the superior and inferior end plates of the surgical segment, and decreasing the risk of cage subsidence.

CONCLUSIONS

With a minimally invasive background, the OLLPS can be used as an alternative to BPS in OLIF and it has better prospects for clinical promotions and applications.

Computational comparison of three different cage porosities in posterior lumbar interbody fusion with porous cage

Porous interbody cages, manufactured using additive laser melting technology, have recently been used in lumbar fusion surgery. The major advantage of a porous cage is the presence of space inside the cage for bone ingrowth. However, the biomechanical effects of different porosities on the lumbar segment with and without bone fusion (ingrowth) are still unclear. Hence, the present study aimed to compare the biomechanical responses, including the stress and range of motion (ROM) of the lumbar L3-L4 segments with three different types of porous cages along with a posterior instrument (PI) with and without bone fusion using computer simulation. A lumbar L3-L4 segment model with a PI and porous cages was used in this study. Three different porosities, namely 12.5, 41.2, and 80.84% were used. The diameter of the pores of the porous cage was uniformly set to 0.5 mm. In addition, a traditional PEEK cage was used in this study. Two different bone statuses, with and without bone fusion (ingrowth into the pores of the porous cage and the inner space of the PEEK cage), were considered. The results indicated that although the contact pressure on the bone surface reduced, the cage stress increased with increasing cage porosity. Furthermore, cage stress and contact pressure also increased in cases with bone fusion compared with those without bone fusion. The contact pressure on the bone surface with a cage porosity of 80.8% decreased by 40% (from 943.1 to 575.5 MPa), 37.7% (from 133 to 82.9 MPa), 40.4% (from 690.8 to 412 MPa), and 34.2% (from 533 to 351.1 MPa), respectively, for flexion, extension, lateral bending, and rotation, respectively, compared with that with a cage porosity of 12.5%. The rotational ROM of the PEEK cage with bone fusion was clearly larger than those of the porous cages. Porous cages have recently become popular owing to improved manufacturing technology. This study provides scientific data on the strength and weakness of porous cages with different porosities for clinical use.

A Dynamic Interbody Cage Improves Bone Formation in Anterior Cervical Surgery: A Porcine Biomechanical Study

BACKGROUND

Anterior cervical discectomy and fusion (ACDF) with a rigid interbody spacer is commonly used in the treatment of cervical degenerative disc disease. Although ACDF relieves clinical symptoms, it is associated with several complications such as pseudoarthrosis and adjacent segment degeneration. The concept of dynamic fusion has been proposed to enhance fusion and reduce implant subsidence rate and post-fusion stiffness; this pilot preclinical animal study was conducted to begin to compare rigid and dynamic fusion in ACDF.

QUESTIONS/PURPOSES

Using a pig model, we asked, is there (1) decreased subsidence, (2) reduced axial stiffness in compression, and (3) improved likelihood of bone growth with a dynamic interbody cage compared with a rigid interbody cage in ACDF?

METHODS

ACDF was performed at two levels, C3/4 and C5/6, in 10 pigs weighing 48 to 55 kg at the age of 14 to 18 months (the pigs were skeletally mature). One level was implanted with a conventional rigid interbody cage, and the other level was implanted with a dynamic interbody cage. The conventional rigid interbody cage was implanted in the upper level in the first five pigs and in the lower level in the next five pigs. Both types of interbody cages were implanted with artificial hydroxyapatite and tricalcium phosphate bone grafts. To assess subsidence, we took radiographs at 0, 7, and 14 weeks postoperatively. Subsidence less than 10% of the disc height was considered as no radiologic abnormality. The animals were euthanized at 14 weeks, and each operated-on motion segment was harvested. Five specimens from each group were biomechanically tested under axial compression loading to determine stiffness. The other five specimens from each group were used for microCT evaluation of bone ingrowth and ongrowth and histologic investigation of bone formation. Sample size was determined based on 80% power and an α of 0.05 to detect a between-group difference of successful bone formation of 15%.

RESULTS

With the numbers available, there was no difference in subsidence between the two groups. Seven of 10 operated-on levels with rigid cages had subsidence on a follow-up radiograph at 14 weeks, and subsidence occurred in two of 10 operated-on levels with dynamic cages (Fisher exact test; p = 0.07). The stiffness of the unimplanted rigid interbody cages was higher than the unimplanted dynamic interbody cages. After harvesting, the median (range) stiffness of the motion segments fused with dynamic interbody cages (531 N/mm [372 to 802]) was less than that of motion segments fused with rigid interbody cages (1042 N/mm [905 to 1249]; p = 0.002). Via microCT, we observed bone trabecular formation in both groups. The median (range) proportions of specimens showing bone ongrowth (88% [85% to 92%]) and bone volume fraction (87% [72% to 100%]) were higher in the dynamic interbody cage group than bone ongrowth (79% [71% to 81%]; p < 0.001) and bone volume fraction (66% [51% to 78%]; p < 0.001) in the rigid interbody cage group. The percentage of the cage with bone ingrowth was higher in the dynamic interbody cage group (74% [64% to 90%]) than in the rigid interbody cage group (56% [32% to 63%]; p < 0.001), and the residual bone graft percentage was lower (6% [5% to 8%] versus 13% [10% to 20%]; p < 0.001). In the dynamic interbody cage group, more bone formation was qualitatively observed inside the cages than in the rigid interbody cage group, with a smaller area of fibrotic tissue under histologic investigation.

CONCLUSION

The dynamic interbody cage provided satisfactory stabilization and percentage of bone ongrowth in this in vivo model of ACDF in pigs, with lower stiffness after bone ongrowth and no difference in subsidence.

CLINICAL RELEVANCE

The dynamic interbody cage appears to be worthy of further investigation. An animal study with larger numbers, with longer observation time, with multilevel surgery, and perhaps in the lumbar spine should be considered.

Biomechanics of adjacent segment after three-level lumbar fusion, hybrid single-level semi-rigid fixation with two-level lumbar fusion

Multi-level spinal fusion has been reported in some cases to lead to adjacent segment disease (ASD) and proximal junctional kyphosis (PJK). The purpose of this study was to demonstrate a polyether-ether-ketone (PEEK) rod fixation system implanted adjacent to a two-level lumbar fusion would have a lower risk of PJK than three-level lumbar fusion, which was investigated by comparing the biomechanical effects on the adjacent level after surgical procedures. Four finite element (FE) models of the lumbar-sacral spine (intact model (INT), L4-S1 fusion model (L4-S1 FUS), L3-S1 fusion model (L3-S1 FUS), and single-level PEEK rod semi-rigid fixation adjacent to L4-S1 fusion model (FUSPRF)) were established. Displacement-controlled finite element (FE) analysis was used during the simulation. Compared with the two-level fusion model (L4-S1 FUS), both three-level implanted models (L3-S1 FUS and FUSPRF) showed an increase intersegmental rotation angle, and maximum von-Mises stress on the disc annulus. The results also showed that the intersegmental rotation, stress on the disc annulus and maximum stress on the rod were lower in the FUSPRF model than the L3-S1 FUS model. Though the maximum screw stress was higher in the FUSPRF model than the L3-S1 FUS model under all moments except for torsion, the maximum screw stress in the two models were far below the yield strength of titanium alloy. As the parameters above have been indicated as risk factors for PJK, it can be concluded that hybrid single-level PEEK rod semi-rigid fixation and two-level lumbar fusion have a lower risk of PJK than three-level lumbar fusion.

Biomechanical role of osteoporosis in the vibration characteristics of human spine after lumbar interbody fusion

Lumbar vertebrae osteoporosis is the most common challenge for lumbar interbody fusion, and this challenge has been widely concerned by scholars for many years. However, under whole-body vibration, osteoporosis how to affect the vibration characteristics of the fusion lumbar spine, complications, and fusion outcomes is urgent to know. The L1-L5 finite element model of lumbar spine was modified to simulate the transforaminal lumbar interbody fusion model with the bilateral pedicle screw fixator at L4-L5 level. A 5 Hz, 40 N sinusoidal vertical load supplemented with a 400 N preload was used to simulate the vertical vibration of human body. The results showed that under whole-body vibration, osteoporosis of fused vertebrae may cause the adjacent segments more unstable and increase the risk of adjacent segment diseases, subsidence, cage failure, rod failure, and lumbar instability. Osteoporosis of the fused vertebrae may cause the vertebral cells an unstable, inhibited growth and lead to poorer fusion outcomes. The findings may assist us in understanding the effect of osteoporosis on the vibration characteristics of lumbar spine fusion and provide references to clinical treatments for lumbar interbody fusion and lumbar vertebrae osteoporosis.

Comparison of dynamic response of three TLIF techniques on the fused and adjacent segments under vibration

To explore which TLIF techniques are advantageous in reducing the risk of complications and conducive to bone fusion under the vibration. The L1-L5 finite element lumbar model was modified to simulate three different TLIF techniques (a unilateral standard cage, a crescent-shaped cage, and bilateral standard cages). The results showed that the crescent-shaped cage may reduce the risk of subsidence and provide a more stable and suitable environment for vertebral cell growth under the vibration compared to the other TLIF techniques. Unilateral cage may increase the risk of adjacent segment disease and cage failure including fatigue failure under vibration.

Subsidence of Additively-Manufactured Cages in Foam Substrates: Effect of Contact Topology

Subsidence of implants into bone is a major source of morbidity. The underlying mechanics of the phenomenon are not clear, but are likely related to interactions between contact stresses and the underlying porous trabecular bone structure. To gain insight into these interactions, we studied the penetration of three-dimensional (3D)-printed indenters with systematically varying geometries into Sawbones® foam substrates and isolated the effects of contact geometry from those of overall contact size and area. When size, contact area, and indented material stiffness and strength are controlled for, we show that resistance to penetration is in fact a function of topology only. Indenters with greater line contact lengths support higher subsidence loads in compression. These results have direct implications for the design of implants to resist subsidence into bone.

Development and Validation of a Computationally Efficient Finite Element Model of the Human Lumbar Spine: Application to Disc Degeneration

INTRODUCTION

This study develops and validates an accurate, computationally efficient, 3-dimensional finite element model (FEM) of the human lumbar spine. Advantages of this simplified model are shown by its application to a disc degeneration study that we demonstrate is completed in one-sixth the time required when using more complicated computed tomography (CT) scan-based models.

METHODS

An osseoligamentous FEM of the L1-L5 spine is developed using simple shapes based on average anatomical dimensions of key features of the spine rather than CT scan images. Pure moments of 7.5 Nm and a compressive follower load of 1000 N are individually applied to the L1 vertebra. Validation is achieved by comparing rotations and intradiscal pressures to other widely accepted FEMs and in vitro studies. Then degenerative disc properties are modeled and rotations calculated. Required computation times are compared between the model presented in this paper and other models developed using CT scans.

RESULTS

For the validation study, parameter values for a healthy spine were used with the loading conditions described above. Total L1-L5 rotations for flexion, extension, lateral bending, and axial rotation under pure moment loading were calculated as 20.3°, 10.7°, 19.7°, and 10.3°, respectively, and under a compressive follower load, maximum intradiscal pressures were calculated as 0.68 MPa. These values compare favorably with the data used for validation. When studying the effects of disc degeneration, the affected segment is shown to experience decreases in rotations during flexion, extension, and lateral bending (24%-56%), while rotations are shown to increase during axial rotation (14%-40%). Adjacent levels realize relatively minor changes in rotation (1%-6%). This parametric study required 17.5 hours of computation time compared to more than 4 days required if utilizing typical published CT scan-based models, illustrating one of the primary advantages of the model presented in this article.

CONCLUSIONS

The FEM presented in this article produces a biomechanical response comparable to widely accepted, complex, CT scan-based models and in vitro studies while requiring much shorter computation times. This makes the model ideal for conducting parametric studies of spinal pathologies and spinal correction techniques.

Comparison of effects of four interbody fusion approaches on the fused and adjacent segments under vibration

BACKGROUND

Which lumbar fusion approaches having fewer impacts on the lumbar spine, reducing the risk of complications and the most conducive to bone fusion under whole-body vibration is urgent to know.

OBJECTIVES

This study researched the best approach under vibration by comparing the effects of four different approaches on the spine, especially regarding some significant indexes related to complications and outcomes.

METHODS

The L1-L5 finite element model was modified to simulate anterior, posterior, trans-foraminal and direct lateral lumbar interbody fusion approaches with bilateral pedicle screw fixation at L4-L5 level.

FINDINGS

Anterior lumbar interbody fusion decreased the corresponding vibration amplitude of the dynamic response at adjacent segments compared with the other three approaches. Direct lateral lumbar interbody fusion decreased the maximum stress in the cage, the endplates at the fused level, and the maximum compressive stress at the interface between the cage and endplates. The maximum disc height and segmental lordosis of Direct lateral lumbar interbody fusion model were the highest among these fusion approaches.

INTERPRETATION

Anterior lumbar interbody fusion may provide a more stable environment for the adjacent segments under vibration. Direct lateral lumbar interbody fusion may reduce the risk of subsidence, cage failure, and adjacent segment disease. Direct lateral lumbar interbody fusion may provide a more stable and suitable environment for vertebral cell growth and lead to better fusion outcomes. The findings may help us understand the effect of various fusion approaches on lumbar and provide some references for choosing a fusion approach.

Correlating in-situ process monitoring data with the reduction in load bearing capacity of selective laser melted Ti-6Al-4V porous biomaterials

Selective Laser Melting allows for the creation of intricate porous structures, that possess favourable biological properties. These structures are known as porous biomaterials. The focus of this paper is to evaluate the use of an in-line photodiode based process monitoring system, for the monitoring of the operational behaviour of the laser, and to correlate this with the resultant parts mechanical performance. In this study the production scale Renishaw 500M was used to produce porous structures, using Ti-6Al-4V feedstock powder. During the process, a co-axial process monitoring system was utilised to generate data relating to both the meltpool and the operational behaviour of the laser. An advanced scanning technique was used to produce the structures, whereby the laser parameters determine the strut dimensions. In this study, the laser input energy was reduced by 33%, 66% and 100%, at specific layers within the structures. Computer Tomography and Scanning Electron Microscopy was utilised to characterise the affected struts within the structures, while quasi-static compression testing was used to determine the structure's mechanical properties. It was demonstrated that as the level of input energy decreased and the number of affected layers increased, a corresponding decrease in the load bearing capacity of the structures occurred. With the structures experiencing a significant loss in strength also exhibiting a change in the failure mode during compression testing. Data generated during the processing of such structures was compared to the data generated during the processing of control structures, with the difference between the two been calculated on a layer-by-layer basis. A clear correlation was demonstrated between the total level of deviation between the two signal sets and a reduction in the load bearing capacity of the structures. This indicates that by comparing build data to a benchmark data set, valuable information relating to the structural integrity of the porous structures can be obtained.

Integrated Design Approaches for 3D Printed Tissue Scaffolds: Review and Outlook

Emerging 3D printing technologies are enabling the fabrication of complex scaffold structures for diverse medical applications. 3D printing allows controlled material placement for configuring porous tissue scaffolds with tailored properties for desired mechanical stiffness, nutrient transport, and biological growth. However, tuning tissue scaffold functionality requires navigation of a complex design space with numerous trade-offs that require multidisciplinary assessment. Integrated design approaches that encourage iteration and consideration of diverse processes including design configuration, material selection, and simulation models provide a basis for improving design performance. In this review, recent advances in design, fabrication, and assessment of 3D printed tissue scaffolds are investigated with a focus on bone tissue engineering. Bone healing and fusion are examples that demonstrate the needs of integrated design approaches in leveraging new materials and 3D printing processes for specified clinical applications. Current challenges for integrated design are outlined and emphasize directions where new research may lead to significant improvements in personalized medicine and emerging areas in healthcare.

Impact of material properties of intervertebral disc on dynamic response of the human lumbar spine to vertical vibration: a finite element sensitivity study

This study aimed to determine the effect of variations in material properties of the intervertebral disc on dynamic response of the human lumbar spine to vertical vibration using a finite element model of the lumbar L1-S1 motion segment. The present material sensitivity study was conducted by varying elastic moduli for annulus ground substance (AGS), annulus fibers (AF), and nucleus pulposus (NP) in the disc. Transient dynamic analysis was performed initially on the model with basic material property under a sinusoidal vertical vibration load. Subsequently, the same analysis was done for each of the three disc components corresponding to high and low material property cases. The computed results were plotted as a function of time and compared. The AGS property displayed a larger impact on vertebral axial displacement and von Mises stress in AGS, and the AF property displayed a larger impact on disc bulge. In contrast, the NP property had little effect on all the response parameters. Additionally, the intradiscal pressure was found to be not sensitive to any of the disc properties. These findings may be helpful in adoption of appropriate material parameters for the intervertebral disc in finite element model of the lumbar spine used for vibration analysis. Graphical abstract Material property sensitivity analysis on vibration characteristics of the human lumbar spine.

A UK-based pilot study of current surgical practice and implant preferences in lumbar fusion surgery

Lumbar fusion surgery is an established procedure for the treatment of low back pain. Despite the wide set of alternative fusion techniques and existing devices, uniform guidelines are not available yet and common surgical trends are scarcely investigated.The purpose of this UK-based study was to provide a descriptive portrait of current surgeons' practice and implant preferences in lumbar fusion surgery.A UK-based in-person survey was designed for this study and submitted to a group of consultant spinal surgeons (n = 32). Fifteeen queries were addressed based on different aspects of surgeons' practice: lumbar fusion techniques, implant preferences, and bone grafting procedures. Answers were analyzed by means of descriptive statistics.Thirty-two consultant spinal surgeons completed the survey. There was clear consistency on the relevance of a patient-centered management (82.3%), along with a considerable variability of practice on the preferred fusion approach. Fixation surgery was found to be largely adopted (96.0%) and favored over stand-alone cages. With regards to the materials, titanium cages were the most used (54.3%). The geometry of the implants influenced the choice of lumbar cages (81.3%). Specifically, parallel-shape cages were mostly avoided (89.2%) and hyperlordotic cages were preferred at the lower lumbar levels. However, there was no design for lumbar cages which was consistently favored. Autograft bone graft surgeries were the most common (60.0%). Amongst the synthetic options, hydroxyapatite-based bone graft substitutes (76.7%) in injectable paste form (80.8%) were preferred.Current lumbar fusion practice is variable and patient-oriented. Findings from this study highlight the need for large-scale investigative surveys and clinical studies aimed to set specific guidelines for certain pathologies or patient categories.

Design of complex bone internal structure using topology optimization with perimeter control

Large facial bone loss usually requires patient-specific bone implants to restore the structural integrity and functionality that also affects the appearance of each patient. Titanium alloys (e.g., Ti-6Al-4V) are typically used in the interfacial porous coatings between the implant and the surrounding bone to promote stability. There exists a property mismatch between the two that in general leads to complications such as stress-shielding. This biomechanical discrepancy is a hurdle in the design of bone replacements. To alleviate the mismatch, the internal structure of the bone replacements should match that of the bone. Topology optimization has proven to be a good technique for designing bone replacements. However, the complex internal structure of the bone is difficult to mimic using conventional topology optimization methods without additional restrictions. In this work, the complex bone internal structure is recovered using a perimeter control based topology optimization approach. By restricting the solution space by means of the perimeter, the intricate design complexity of bones can be achieved. Three different bone regions with well-known physiological loadings are selected to illustrate the method. Additionally, we found that the target perimeter value and the pattern of the initial distribution play a vital role in obtaining the natural curvatures in the bone internal structures as well as avoiding excessive island patterns.

Biomechanical Analysis of Porous Additive Manufactured Cages for Lateral Lumbar Interbody Fusion: A Finite Element Analysis

BACKGROUND

A porous additive manufactured (AM) cage may provide stability similar to that of traditional solid cages and may be beneficial to bone ingrowth. The biomechanical influence of various porous cages on stability, subsidence, stresses in cage, and facet contact force has not been fully described. The purpose of this study was to verify biomechanical effects of porous AM cages.

METHODS

The surgical finite element models with various cages were constructed. The partially porous titanium (PPT) cages and fully porous titanium (FPT) cages were applied. The mechanical parameters of porous materials were obtained by mechanical test. Then the porous AM cages were compared with solid titanium (TI) cage and solid polyetheretherketone (PEEK) cage. The 4 motion modes were simulated. Range of motion (ROM), cage stress, end plate stress, and facet joint force (FJF) were compared.

RESULTS

For all the surgical models, ROM decreased by >90%. Compared with TI and PPT cages, PEEK and FPT cages substantially reduced the maximum stresses in cage and end plate in all motion modes. Compared with PEEK cages, the stresses in cage and end plate for FPT cages decreased, whereas the ROM increased. Comparing FPT cages, the stresses in cage and end plate decreased with increasing porosity, whereas ROM increased with increasing porosity. After interbody fusion, FJF was substantially reduced in all motion modes except for flexion.

CONCLUSIONS

Fully porous cages may offer an alternative to solid PEEK cages in lateral lumbar interbody fusion. However, it may be prudent to further increase the porosity of the cage.

Computationally designed lattices with tuned properties for tissue engineering using 3D printing

Tissue scaffolds provide structural support while facilitating tissue growth, but are challenging to design due to diverse property trade-offs. Here, a computational approach was developed for modeling scaffolds with lattice structures of eight different topologies and assessing properties relevant to bone tissue engineering applications. Evaluated properties include porosity, pore size, surface-volume ratio, elastic modulus, shear modulus, and permeability. Lattice topologies were generated by patterning beam-based unit cells, with design parameters for beam diameter and unit cell length. Finite element simulations were conducted for each topology and quantified how elastic modulus and shear modulus scale with porosity, and how permeability scales with porosity cubed over surface-volume ratio squared. Lattices were compared with controlled properties related to porosity and pore size. Relative comparisons suggest that lattice topology leads to specializations in achievable properties. For instance, Cube topologies tend to have high elastic and low shear moduli while Octet topologies have high shear moduli and surface-volume ratios but low permeability. The developed method was utilized to analyze property trade-offs as beam diameter was altered for a given topology, and used to prototype a 3D printed lattice embedded in an interbody cage for spinal fusion treatments. Findings provide a basis for modeling and understanding relative differences among beam-based lattices designed to facilitate bone tissue growth.

Biomechanical study of different fixation techniques for the treatment of sacroiliac joint injuries using finite element analyses and biomechanical tests

The pelvis is one of the most stressed areas of the human musculoskeletal system due to the transfer of truncal loads to the lower extremities. Sacroiliac joint injury may lead to abnormal joint mechanics and an unstable pelvis. Various fixation techniques have been evaluated and discussed. However, it may be difficult to investigate each technique due to variations in bone quality, bone anatomy, fracture pattern, and fixation location. Additionally, the finite element method is one useful technology that avoids these variations. Unfortunately, most previous studies neglected the effects of the lumbar spine and femurs when they investigated the biomechanics of pelvises. Thus, the aim of this study was to investigate the biomechanical performance of intact, injured, and treated pelvises using numerical and experimental approaches. Three-dimensional finite element models of the spine-pelvis-femur complex with and without muscles and ligaments were developed. The intact pelvis, the pelvis with sacroiliac joint injury, and three types of pelvic fixation techniques were analyzed. Concurrently, biomechanical tests were conducted to validate the numerical outcomes using artificial pelvises. Posterior iliosacral screw fixation showed relatively better fixation stability and lower risks of implant failure and pelvic breakage than sacral bar fixation and a locking compression plate fixation. The present study can help surgeons and engineers understand the biomechanics of intact, injured, and treated pelvises. Both the simulation technique and the experimental setup can be applied to investigate different pelvic injuries.

Influence of different frequencies of axial cyclic loading on time-domain vibration response of the lumbar spine: A finite element study

Very few studies have quantitatively analyzed influence of the loading frequency on time-domain vibration response of the whole lumbar spine in the presence of a physiologic compressive preload. In this study, a three-dimensional non-linear finite element model of ligamentous L1-S1 segment was developed to predict time-domain dynamic response of the whole lumbar spine to axial cyclic loading with different frequencies. A compressive follower preload of 400 N was applied to the model to simulate the physiologic compressive load. Modal analysis was initially performed to extract axial resonant frequency of the model under a 40 kg upper body mass and the 400 N preload. The result showed that the axial resonant frequency was 7.77 Hz. Subsequently, transient dynamic analyses were performed on the model under a sinusoidal axial load of ±40 N at frequencies of 3, 5, 7, 9, 11, 13 and 15 Hz with the 400 N preload and 40 kg mass. The computational results (strains and stresses in the spinal components) were collected and plotted as a function of time. These predicted results were found to be frequency-dependent and consistent with the notion in engineering dynamics texts that the closer the loading frequency approaches the resonant frequency, the larger the response is. For example, the results for 5 Hz load compared to 3 Hz load showed a 68.6-111.5% increase in peak-to-bottom variations of the predicted response parameters, and the results for 13 Hz load compared to 11 Hz load showed a 26.4-37.8% decrease in these variations.