Notch sensitivity jeopardizes titanium locking plate fatigue strength

Bone Plates Runout Prediction Through Tensile Strength and Geometric Properties for Regulatory Mechanical Testing

Mechanical tests on bone plates are mandatory for regulatory purposes and, typically, the ASTM F382 standard is used, which involves a four-point bending test setup to evaluate the cyclic bending fatigue performance of the bone plate. These test campaigns require a considerable financial outlay and long execution times; therefore, an accurate prediction of experimental outcomes can reduce test runtime with beneficial cost cuts for manufacturers. Hence, an analytical framework is here proposed for the direct estimation of the maximum bending moment of a bone plate under fatigue loading, to guide the identification of the runout load for regulatory testing. Eleven bone plates awaiting certification were subjected to a comprehensive testing campaign following ASTM F382 protocols to evaluate their static and fatigue bending properties. An analytical prediction of the maximum bending moment was subsequently implemented based on ultimate strength and plate geometry. The experimental loads obtained from fatigue testing were then used to verify the prediction accuracy of the analytical approach. Results showed promising predictive ability, with R2 coefficients above 0.95 in the runout condition, with potential impact in reducing the experimental tests needed for the CE marking of bone plates.

Design considerations for patient-specific bone fixation plates: a literature review

In orthopedic surgery, patient-specific bone plates are used for fixation when conventional bone plates do not fit the specific anatomy of a patient. However, plate failure can occur due to a lack of properly established design parameters that support optimal biomechanical properties of the plate.This review provides an overview of design parameters and biomechanical properties of patient-specific bone plates, which can assist in the design of the optimal plate.A literature search was conducted through PubMed and Embase, resulting in the inclusion of 78 studies, comprising clinical studies using patient-specific bone plates for fracture fixation or experimental studies that evaluated biomechanical properties or design parameters of bone plates. Biomechanical properties of the plates, including elastic stiffness, yield strength, tensile strength, and Poisson's ratio are influenced by various factors, such as material properties, geometry, interface distance, fixation mechanism, screw pattern, working length and manufacturing techniques.Although variations within studies challenge direct translation of experimental results into clinical practice, this review serves as a useful reference guide to determine which parameters must be carefully considered during the design and manufacturing process to achieve the desired biomechanical properties of a plate for fixation of a specific type of fracture.

Trust But Verify: Design Differences in The Prevention of Targeting Errors in Cephalomedullary Nails

OBJECTIVES

To evaluate insertional damage on explanted cephalomedullary nails and to differentiate typical from atypical wear to characterize outliers.

DESIGN

Therapeutic.

SETTING

Level II trauma center.

PARTICIPANTS

Patients who underwent removal of an implanted cephalomedullary nail for any reason from 2015 to 2023.

METHODS

Inspection of implants was performed at ×1000 magnification with a light microscope. Benchtop testing was performed with Gamma3, Gamma4, Intertan, TFN, and TFNa instrumentation.

RESULTS

One hundred nine cephalomedullary nails were inspected. Insertional damage was observed in more than 95% of the implants recovered. In 34% (37 of 109) of implants, damage to the proximal aperture was severe enough to cause a chamfer or "notch." Chamfers were also encountered along the distal locking aperture in short stem implants in 44% (19 of 43). Guidewire chamfers to the proximal implant external to the aperture and damage to preinserted set screws were outliers. Evidence of set screw fracture or deformity was encountered in 12 specimens. Four anomalous set screw variants were encountered within 1 implant design, each variant exhibiting maltracking with deployment that could result in malfunction.

CONCLUSIONS

Insertional damage to cephalomedullary implants was encountered routinely among the explants and should not always be categorized as preventable surgical error. Surgeons should be familiar with technical and design factors that contribute to chamfering of implants to reduce failures.

LEVEL OF EVIDENCE

Therapeutic, Level III.

Effects of merged holes, partial thread removal, and offset holes on fatigue strengths of titanium locking plates

BACKGROUND

This study investigated the effects of screw hole merging, thread removal, and screw hole offset on the mechanical properties of locking plates.

METHODS

Finite element models were used to develop the optimal design of the merged holes. Four titanium locking plates with different hole designs were analyzed. Type I had threaded round holes. Type II had merged holes. Type III had merged holes with partial thread removal. Type IV had threaded offset holes. Mechanical experiments similar to finite element analyses were conducted and compared. Screw bending tests were used to assess the screw holding power.

FINDINGS

Finite element analyses showed the optimal merging distance between two round screw holes was 3.5 mm with 2/3 circumferences in each hole. The stresses of types II and III were respectively 6.42% and 7.33%, lower than that of type I. The stress of type IV was 1.66% higher than that of type I. In the mechanical tests, the fatigue lives of types II and III were respectively 3.86 and 7.16 times higher than that of type I. The fatigue life of type IV was 37% lower than that of type I. The differences in the bending strengths of screws were insignificant.

INTERPRETATION

Merging holes could mitigate screw hole stress and increase the fatigue lives of the plates significantly. Partial thread removal could further improve the fatigue life. Merging holes and thread removal did not decrease the screw holding power significantly. The fatigue lives were significantly decreased in plates with offset holes.

Comparison of Early Fatigue Failure of the TFNa and Gamma 3 Cephalomedullary Nails in the United States From 2015 to 2019

OBJECTIVES

To compare reports of implant fatigue failure submitted to the FDA of 2 commonly used cephalomedullary nails.

METHODS

In total, 2724 medical device reports from the FDA's MAUDE database from Jan 2015 to Oct 2019 were reviewed for the Trochanteric Femoral Nail-Advanced (TFNa) and Gamma 3 implants.

RESULTS

Data from 342 implant failures included in the MAUDE database were analyzed. TFNa and Gamma 3 had 183 and 159 reported fatigue failures, respectively. All failed implants fractured in the same location through the proximal screw aperture. Time from implantation to failure was on average 2 months shorter for TFNa implants that were reported fractured than for Gamma 3 implants reported, a difference that was statistically significant (P < 0.05). In total, 100 implants were reported to have failed within the first 4 months (53 and 47 for TFNa and Gamma 3, respectively). For Gamma 3 implants that failed in the first 4 months, almost all of the available manufacturers' inspection reports revealed implant notches at the point of failure from drilling. For TFNa implants that failed early, only one reported notch was noted in the available inspection reports.

CONCLUSIONS

In contrast to other studies regarding fatigue failure, reported failures in both TFNa and Gamma 3 occurred earlier than can be attributed to delayed or nonunion. The reported failures of the TFNa in the MAUDE database occurred earlier than did those of the Gamma 3. Early failures of the Gamma 3 seemed to be the result of iatrogenic implant notching.

LEVEL OF EVIDENCE

Therapeutic Level III. See instructions for authors for a complete description of levels of evidence.

Fatigue Crack Growth and Fracture of Internal Fixation Materials in In Vivo Environments-A Review

The development of crack patterns is a serious problem affecting the durability of orthopedic implants and the prognosis of patients. This issue has gained considerable attention in the medical community in recent years. This literature focuses on the five primary aspects relevant to the evaluation of the surface cracking patterns, i.e., inappropriate use, design flaws, inconsistent elastic modulus, allergic reaction, poor compatibility, and anti-corrosiveness. The hope is that increased understanding will open doors to optimize fabrication for biomedical applications. The latest technological issues and potential capabilities of implants that combine absorbable materials and shape memory alloys are also discussed. This article will act as a roadmap to be employed in the realm of orthopedic. Fatigue crack growth and the challenges associated with materials must be recognized to help make new implant technologies viable for wider clinical adoption. This review presents a summary of recent findings on the fatigue mechanisms and fracture of implant in the initial period after surgery. We propose solutions to common problems. The recognition of essential complications and technical problems related to various approaches and material choices while satisfying clinical requirements is crucial. Additional investigation will be needed to surmount these challenges and reduce the likelihood of fatigue crack growth after implantation.

Half-threaded holes markedly increase the fatigue life of locking plates without compromising screw stability

Aims

To determine whether half-threaded screw holes in a new titanium locking plate design can substantially decrease the notch effects of the threads and increase the plate fatigue life.

Methods

Three types (I to III) of titanium locking plates were fabricated to simulate plates used in the femur, tibia, and forearm. Two copies of each were fabricated using full- and half-threaded screw holes (called A and B, respectively). The mechanical strengths of the plates were evaluated according to the American Society for Testing and Materials (ASTM) F382-14, and the screw stability was assessed by measuring the screw removal torque and bending strength.

Results

The B plates had fatigue lives 11- to 16-times higher than those of the A plates. Before cyclic loading, the screw removal torques were all higher than the insertion torques. However, after cyclic loading, the removal torques were similar to or slightly lower than the insertion torques (0% to 17.3%), although those of the B plates were higher than those of the A plates for all except the type III plates (101%, 109.8%, and 93.8% for types I, II, and III, respectively). The bending strengths of the screws were not significantly different between the A and B plates for any of the types.

Conclusion

Removing half of the threads from the screw holes markedly increased the fatigue life of the locking plates while preserving the tightness of the screw heads and the bending strength of the locking screws. However, future work is necessary to determine the relationship between the notch sensitivity properties and titanium plate design.Cite this article: Bone Joint Res 2020;9(10):645-652.

Contouring Plates in Fracture Surgery: Indications and Pitfalls

Effective fracture surgery requires contouring orthopaedic implants in multiple planes. The amount of force required for contouring is dependent on the amount and type of material contained within the plane to be altered. The type of contouring used depends on the desired plate function; for example, buttress mode often requires some degree of undercontouring, whereas compression plating may require prebending. Other reasons to contour a plate include matching patient anatomy either to maximize fixation options or to reduce implant prominence. Precontoured plates can be convenient and help to facilitate soft-tissue friendly techniques but have the potential to introduce malreduction if the plate position and fit are not carefully monitored.

A novel adjustable locking plate (ALP) for segmental bone fracture treatment

A novel Ti6Al4V adjustable locking plate (ALP) is designed to provide enhanced bone stability for segmental bone fractures and to allow precise positioning of disconnected segments. The design incorporates an adjustable rack and pinion mechanism to perform compression, distraction and segment transfer during plate fixation surgery. The aim of this study is to introduce the advantages of the added feature and computationally characterize the biomechanical performance of the proposed design. Structural strength of the novel plate is analyzed using numerical methods for 4-point bending and fatigue properties, following ASTM standards. An additional mechanical failure finite element test is also conducted on the rack and pinion to reveal how much torque can be safely applied to the mechanism by the surgeon. Simulation results predict that the new design is sufficiently strong to not fail under regular anatomical loading scenarios with close bending strength and fatigue life properties to clinically used locking compression plates. The novel ALP design is expected to be a good candidate for addressing problems regarding fixation of multi-fragmentary bone fractures.

Screw head plugs increase the fatigue strength of stainless steel, but not of titanium, locking plates

Objectives

Screw plugs have been reported to increase the fatigue strength of stainless steel locking plates. The objective of this study was to examine and compare this effect between stainless steel and titanium locking plates.

Methods

Custom-designed locking plates with identical structures were fabricated from stainless steel and a titanium alloy. Three types of plates were compared: type I unplugged plates; type II plugged plates with a 4 Nm torque; and type III plugged plates with a 12 Nm torque. The stiffness, yield strength, and fatigue strength of the plates were investigated through a four-point bending test. Failure analyses were performed subsequently.

Results

For stainless steel, type II and type III plates had significantly higher fatigue strength than type I plates. For titanium, there were no significant differences between the fatigue strengths of the three types of plates. Failure analyses showed local plastic deformations at the threads of screw plugs in type II and type III stainless steel plates but not in titanium plates.

Conclusion

The screw plugs could increase the fatigue strength of stainless steel plates but not of titanium plates. Therefore, leaving screw holes open around fracture sites is recommended in titanium plates.

Cite this article: L-W. Hung, C-K. Chao, J-R. Huang, J. Lin. Screw head plugs increase the fatigue strength of stainless steel, but not of titanium, locking plates. Bone Joint Res 2018;7:629–635. DOI: 10.1302/2046-3758.712.BJR-2018-0083.R1.

Modification of the screw hole structures to improve the fatigue strength of locking plates

BACKGROUND

The fatigue fracture of locking plates can substantially threaten fracture treatment results. In the present study, three measures for modifying the screw hole structures of plates were implemented to improve their fatigue strength.

MATERIALS

Custom-made identical titanium locking plates, except the screw hole configurations, were tested using four-point bending load. The three measures were partial removal of screw threads on the tension side of the plates, reduction of screw hole size, and modification of the thread radii. There were six types of plates: control (Type I), half of the threads removed (Type II) or one-third of the threads (Type III), smaller screw holes (Type IV), and increase of the thread root radii (Type V) or crest radii (Type VI).

FINDINGS

Compared with the control, Types II and III significantly improved the fatigue strength (14.5 and 10.1 times, respectively). Decreasing the size of the screw hole (Type IV) also yielded a higher fatigue strength (17.6%). Type VI significantly improved the fatigue strength (9.8 times). However, Type V decreased the fatigue strength (14%). For cyclic stiffness, Type IV was significantly higher than other types statistically. Failure analyses showed typical fatigue fracture in all plates and the cracks were always initiated at the thread crest.

INTERPRETATIONS

The fatigue strength of titanium locking plates can be significantly improved by structural changes in the screw holes. Removing the threads of the plates and increasing the crest radii of the threads were more effective measures than decreasing the size of the screw holes.