Analysis of wear asymmetry in a series of 94 retrieved polyethylene tibial bearings

3D patient imaging and retrieval analysis help understand the clinical importance of rotation in knee replacements

PURPOSE

The purpose of the present study was to correlate highly accurate CT measurements of pre-revision total knee arthroplasty (TKA) implant position with findings of retrieval analysis post-revision, to understand the clinical relevance of TKA orientation.

METHODS

This study involved 53 retrieved TKA implants with pre-revision 3D-CT scans used to determine coronal (varus-valgus), sagittal (tibial slope) and rotational (internal rotation-external rotation) TKA orientation as well as tibiofemoral leg axis. Differences between femoral and tibial angles to describe the "relative rotational mismatch" were also calculated. All tibial inserts were forensically analyzed using the Hood score. Statistical analysis was performed to investigate correlations between TKA component orientation and surface damage (p < 0.05).

RESULTS

Femoral components were found to have axial rotations mainly within ± 3° (68%), whilst 45% of the tibial components and 66% of the relative rotational mismatches were > 3° and < - 3°, respectively. The majority of femoral and tibial components (87% in both cases), as well as the femorotibial angle (70%), showed coronal orientations within ± 3°. The 64% of the tibial components showed posterior tibial slopes out of both the 0°-3° and 5°-7° ranges. There was a significant correlation between tibial slope and damage score on polyethylene tibial inserts (r = 0.2856; p = 0.0382) as well as a significant correlation between implants' position in the axial plane and damage score on polyethylene tibial inserts (r = 0.6537, p = 0.0240).

CONCLUSIONS

This is the first study to use accurate measurements from pre-revision 3DCT to compare tibial and femoral orientation in all three planes with retrieval findings in total knee replacements. A significant correlation between implant position and polyethylene surface damage was found. These results showed the importance of optimizing component position to minimize polyethylene damage. Further analysis involving more accurate polyethylene wear measurements are fundamental to fully understand the role of components' orientation in TKAs.

Load application for the contact mechanics analysis and wear prediction of total knee replacement

Tibiofemoral contact forces in total knee replacement have been measured at the medial and lateral sites respectively using an instrumented prosthesis, and predicted from musculoskeletal multibody dynamics models with a reasonable accuracy. However, it is uncommon that the medial and lateral forces are applied separately to replace a total axial load according to the ISO standard in the majority of current finite element analyses. In this study, we quantified the different effects of applying the medial and lateral loads separately versus the traditional total axial load application on contact mechanics and wear prediction of a patient-specific knee prosthesis. The load application position played an important role under the medial-lateral load application. The loading set which produced the closest load distribution to the multibody dynamics model was used to predict the contact mechanics and wear for the prosthesis and compared with the total axial load application. The medial-lateral load distribution using the present method was found to be closer to the multibody dynamics prediction than the traditional total axial load application, and the maximum contact pressure and contact area were consistent with the corresponding load variation. The predicted total volumetric wear rate and area were similar between the two load applications. However, the split of the predicted wear volumes on the medial and the lateral sides was different. The lateral volumetric wear rate was 31.46% smaller than the medial from the traditional load application prediction, while from the medial-lateral load application, the lateral side was only 11.8% smaller than the medial. The medial-lateral load application could provide a new and more accurate method of load application for patient-specific preclinical contact mechanics and wear prediction of knee implants.

An autonomous mathematical reconstruction to effectively measure volume loss on retrieved polyethylene tibial inserts

Wear of the polyethylene tibial component is a major factor in the success of total knee replacements. However, sampling resolution and the challenges of estimating original surfaces with relatively complex articulating geometries have limited the accuracy of volumetric measurements of wear on surgically retrieved inserts. A mathematical model analyzed volume error due to sampling resolution and found that 100 × 100 μm(2) point spacing reduced error below 1 mm(3). Small volumes of material were progressively removed from the topside of three unworn tibial inserts, after which each component was weighed and digitized with a laser coordinate measuring machine. Six inserts worn in knee simulator tests and nine surgically retrieved inserts visually scored for damage were also digitized. For these tests, the original surface of an insert was mathematically reconstructed from unworn regions of the same component, and volume loss and its spatial distribution were calculated. Volume loss estimated by autonomous reconstruction correlated strongly to mass removed manually (R(2) = 0.954, slope = 1.02 ± 0.04), mass lost during simulator testing (R(2) = 0.935, slope = 1.01 ± 0.07) and visual damage scores separated by size (R(2)large = 0.9824, R(2)small = 0.9728). These results suggest that an autonomous mathematical reconstruction can be used to effectively measure volume loss in retrieved tibial inserts.

Comparison of polyethylene tibial insert damage from in vivo function and in vitro wear simulation

Function and wear of total knee arthroplasties were compared by analysis of damage patterns on polyethylene tibial inserts retrieved from patients (Group R) with inserts obtained after in vitro force-controlled knee joint wear simulation. Two simulator input profiles were evaluated, including standard walking (Group W), and combined walking and stair descent (Group W + S), simulating varied activities and a more severe physiological environment. Damage regions on all inserts were quantitatively assessed. On average, inserts in all groups had internally rotated damage patterns and the greatest articular deformation in the lateral compartment. These patterns were more pronounced in Group W + S compared to Group W. Deformation rates of simulated inserts were analogous to about six years of physiologic function. However, both groups of simulated inserts generally underestimated the magnitude of damage area and extent observed on retrieved inserts, consistent with differences in the simulator's tibiofemoral contact mechanics and those known to occur in patients during functional activities. Modification of simulator inputs, such as the increased anteroposterior excursion and more severe loading conditions in Group W + S, can generate greater wear volume, larger damage areas, and increased surface deformation rates compared to standard inputs.

In vivo contact kinematics and contact forces of the knee after total knee arthroplasty during dynamic weight-bearing activities

Analysis of polyethylene component wear and implant loosening in total knee arthroplasty (TKA) requires precise knowledge of in vivo articular motion and loading conditions. This study presents a simultaneous in vivo measurement of tibiofemoral articular contact forces and contact kinematics in three TKA patients. These measurements were accomplished via a dual fluoroscopic imaging system and instrumented tibial implants, during dynamic single leg lunge and chair rising-sitting. The measured forces and contact locations were also used to determine mediolateral distribution of axial contact forces. Contact kinematics data showed a medial pivot during flexion of the knee, for all patients in the study. Average axial forces were higher for lunge compared to chair rising-sitting (224% vs. 187% body weight). In this study, we measured peak anteroposterior and mediolateral forces averaging 13.3% BW during lunge and 18.5% BW during chair rising-sitting. Mediolateral distributions of axial contact force were both patient and activity specific. All patients showed equitable medial-lateral loading during lunge but greater loads at the lateral compartment during chair rising-sitting. The results of this study may enable more accurate reproduction of in vivo loads and articular motion patterns in wear simulators and finite element models. This in turn may help advance our understanding of factors limiting longevity of TKA implants, such as aseptic loosening and polyethylene component wear, and enable improved TKA designs.

Clinical wear measurement on low contact stress rotating platform knee bearings

Whereas fixed-bearing total knee arthroplasty (TKA) designs secure the polyethylene bearing to the tibial tray, mobile-bearing TKAs allow the bearing to move relative to the tray. This study evaluated wear performance of the rotational articulation of the Low Contact Stress Rotating Platform mobile-bearing TKA (DePuy, Warsaw, Ind) by analyzing 100 retrievals. All retrieved bearings showed rotation surface damage, but severity of the damage did not correlate with duration. Rotation surface damage appeared to be caused by contaminant particles, which produced curvilinear scratches that were longer than the normal rotational excursion of the knee. Wear measurement indicated that wear was relatively uniform, long-term wear rates were low (mean, 54 mm(3)/y for durations >2 years) and decreased with longer duration, and damaged appearance did not correspond to high wear.

Patient and surgery related factors associated with fatigue type polyethylene wear on 49 PCA and DURACON retrievals at autopsy and revision

Background

Polyethylene wear is an important factor for longevity of total knee arthroplasty. Proven and suspicious factors causing wear can be grouped as material, patient and surgery related. There are more studies correlating design and/or biomaterial factors to in vivo wear than those to patient and surgery related factors. Many retrieval studies just include revision implants and therefore may not be representative. This study is aimed to correlate patient- and surgery- related factors to visual wear score by minimizing design influence and include both autopsy and revision implants. Comparison between the groups was expected to unmask patient and surgery-related factors responsible for wear.

Methods

The amount of joint side wear on polyethylene retrievals was measured using a modification of an established visual wear score. Fatigue type wear was defined as summation of the most severe wear modes of delamination, pitting and cracks. Analysis of patient and surgery related variables suspicious to cause wear included prospectively sampled patient activity which was measured by self reported walking capacity. Statistical analysis was done by univariate analysis of variance. Activity level and implantation time were merged to an index of use and correlated to the wear score.

Results

Wear score after comparable implantation time was significantly less in the autopsy group. Even so, fatigue type wear accounted for 84 and 93 % of total wear score on autopsy and revision implants respectively. A highly significant influence on wear score was found in time of implantation (p = 0.002), level of activity (p = 0.025) and inserts belonging to revision group (p = 0.006). No influence was found for the kind of patella replacement (p = 0.483). Body mass index and accuracy of component alignment had no significant influence on visual wear score. Fatigue-type wear in the medial compartment was closely correlated to the index of use in the autopsy (R² = 0.383) and the revision group (R² = 0.813).

Conclusion

The present study's finding of substantial fatigue type wear in both autopsy and revision retrievals supports the theory that polyethylene fatigue strength is generally exceeded in this type of prosthesis. Furthermore, this study correlated fatigue-type polyethylene wear to an index of use as calculated by activity over time. Future retrieval studies may use activity over time as an important patient related factor correlated to the visual wear score. When evaluating total knee arthroplasty routine follow up, the surgeon must think of substantial wear present even without major clinical signs.

High-flexion TKA designs: what are their in vivo contact mechanics?

To accommodate for high flexion, new total knee arthroplasties (TKAs) have been designed. Unlike older designs which have been found to exhibit decreasing contact area with increasing flexion, we hypothesized the new designs would be associated with improved contact mechanics. We compared in vivo contact mechanics for 10 subjects having a fixed-bearing high-flexion posterior-stabilized (LPS-Flex) TKA and 10 subjects having a fixed-bearing high-flexion posterior cruciate-retaining (CR-Flex) TKA. All subjects performed deep knee bends to maximum flexion while under fluoroscopic surveillance. In vivo kinematics obtained using a three-dimensional to two-dimensional registration technique, were input into a three-dimensional inverse dynamic mathematical model to determine the contact forces. The contact areas and contact stresses were determined using a deformable contact model. The contact forces, contact areas, and contact stresses in both these implants increased with increasing flexion. The medial contact area in the LPS-Flex was higher than the CR-Flex for most of the flexion cycle. The lateral contact area was higher in the CR-Flex than the LPS-Flex in early and midflexion ranges. Although the lateral contact stresses were similar in both implants, the CR-Flex experienced higher medial contact stress than the LPS-Flex throughout flexion. However, both these implants were able to maintain sufficient contact area so the contact stress values were well below the yield strength of crosslinked polyethylene.

Digital photogrammetry for quantitative wear analysis of retrieved TKA components

The use of new materials in knee arthroplasty demands a way in which to accurately quantify wear in retrieved components. Methods such as damage scoring, coordinate measurement, and in vivo wear analysis have been used in the past. The limitations in these methods illustrate a need for a different methodology that can accurately quantify wear, which is relatively easy to perform and uses a minimal amount of expensive equipment. Off-the-shelf digital photogrammetry represents a potentially quick and easy alternative to what is readily available. Eighty tibial inserts were visually examined for front and backside wear and digitally photographed in the presence of two calibrated reference fields. All images were segmented (via manual and automated algorithms) using Adobe Photoshop and National Institute of Health ImageJ. Finally, wear was determined using ImageJ and Rhinoceros software. The absolute accuracy of the method and repeatability/reproducibility by different observers were measured in order to determine the uncertainty of wear measurements. To determine if variation in wear measurements was due to implant design, 35 implants of the three most prevalent designs were subjected to retrieval analysis. The overall accuracy of area measurements was 97.8%. The error in automated segmentation was found to be significantly lower than that of manual segmentation. The photogrammetry method was found to be reasonably accurate and repeatable in measuring 2-D areas and applicable to determining wear. There was no significant variation in uncertainty detected among different implant designs. Photogrammetry has a broad range of applicability since it is size- and design-independent. A minimal amount of off-the-shelf equipment is needed for the procedure and no proprietary knowledge of the implant is needed.

Contribution of loading conditions and material properties to stress shielding near the tibial component of total knee replacements

This communication reports important preliminary results of a parametric analysis into the stress shielding effects of loading conditions and material properties of a total knee replacement (TKR) prosthesis. A previously developed finite element (FE) model of the proximal tibia that incorporated orthotropic and heterogeneous bone properties was used. Tibiofemoral joint compression and soft tissue (ligament and muscle) forces were also included to better represent the loading condition in the tibia. Stress shielding effects were studied for a prosthesis similar to a commercially available model. Results from the model show that the hypothesis of relatively higher Young's modulus of implant compared to bone as the primary cause of stress shielding is not sufficiently descriptive. Loading conditions as a result of altered bone or implant condylar surface geometry, load placement on the condylar surface, and load pattern created by the TKR are at least as important or, in some cases, more important factors in observed stress shielding immediately post-operation. This finding can be used to focus new implant design on altered loading conditions as well as material selection.