Porous fusion cage design via integrated global-local topology optimization and biomechanical analysis of performance

Subsidence Rates Associated With Porous 3D-Printed Versus Solid Titanium Cages in Transforaminal Lumbar Interbody Fusion

STUDY DESIGN

Retrospective Cohort Study.

OBJECTIVE

To determine whether 3D-printed porous titanium (3DPT) interbody cages offer any clinical or radiographic advantage over standard solid titanium (ST) interbody cages in transforaminal lumbar interbody fusions (TLIF).

METHODS

A consecutive series of adult patients undergoing one- or two-level TLIF with either 3DPT or ST "banana" cages were analyzed for patient reported outcome measures (PROMs), radiographic complications, and clinical complications. Exclusion criteria included clinical or radiographic follow-up less than 1 year.

RESULTS

The final cohort included 90 ST interbody levels from 74 patients, and 73 3DPT interbody levels from 50 patients for a total of 124 patients. Baseline demographic variables and comorbidity rates were similar between groups (P > .05). Subsidence of any grade occurred more frequently in the ST group compared with the 3DPT group (24.4% vs 5.5%, respectively, P = .001). Further, the ST group was more likely to have higher grades of subsidence than the 3DPT group (P = .009). All PROMs improved similarly after surgery and revision rates did not differ between groups (both P > .05). On multivariate analysis, significant positive correlators with increasing subsidence grade included greater age (P = .015), greater body mass index (P = .043), osteoporosis/osteopenia (P < .027), and ST cage type (P = .019).

CONCLUSIONS

When considering interbody material for TLIF, both ST and 3DPT cages performed well; however, 3DPT cages were associated with lower rates of subsidence. The clinical relevance of these findings deserves further randomized, prospective investigation.

Mechano-driven intervertebral bone bridging via oriented mechanical stimulus in a twist metamaterial cage: An in silico study

Stiffer cages provide sufficient mechanical support but fail to promote bone ingrowth due to stress shielding. It remains challenging for fusion cage to satisfy both bone bridging and mechanical stability. Here we designed a fusion cage based on twist metamaterial for improved bone ingrowth, and proved its superiority to the conventional diagonal-based cage in silico. The fusion process was numerically reproduced via an injury-induced osteogenesis model and the mechano-driven bone remodeling algorithm, and the outcomes fusion effects were evaluated by the morphological features of the newly-formed bone and the biomechanical behaviors of the bone-cage composite. The twist-based cages exhibited oriented bone formation in the depth direction, in comparison to the diagonal-based cages. The axial stiffness of the bone-cage composites with twist-based cages was notably higher than that with diagonal-based cages; meanwhile, the ranges of motion of the twist-based fusion segment were lower. It was concluded that the twist metamaterial cages led to oriented bone ingrowth, superior mechanical stability of the bone-cage composite, and less detrimental impacts on the adjacent bones. More generally, metamaterials with a tunable displacement mode of struts might provide more design freedom in implant designs to offer customized mechanical stimulus for osseointegration.

Customized design and biomechanical property analysis of 3D-printed tantalum intervertebral cages

BACKGROUND

Intervertebral cages used in clinical applications were often general products with standard specifications, which were challenging to match with the cervical vertebra and prone to cause stress shielding and subsidence.

OBJECTIVE

To design and fabricate customized tantalum (Ta) intervertebral fusion cages that meets the biomechanical requirements of the cervical segment.

METHODS

The lattice intervertebral cages were customized designed and fabricated by the selective laser melting. The joint and muscle forces of the cervical segment under different movements were analyzed using reverse dynamics method. The stress characteristics of cage, plate, screws and vertebral endplate were analyzed by finite element analysis. The fluid flow behaviors and permeability of three lattice structures were simulated by computational fluid dynamics. Compression tests were executed to investigate the biomechanical properties of the cages.

RESULTS

Compared with the solid cages, the lattice-filled structures significantly reduced the stress of cages and anterior fixation system. In comparison to the octahedroid and quaddiametral lattice-filled cages, the bitriangle lattice-filled cage had a lower stress shielding rate, higher permeability, and superior subsidence resistance ability.

CONCLUSION

The inverse dynamics simulation combined with finite element analysis is an effective method to investigate the biomechanical properties of the cervical vertebra during movements.

Design of 3D-printed prostheses for reconstruction of periacetabular bone tumors using topology optimization

Background: Prostheses for the reconstruction of periacetabular bone tumors are prone to instigate stress shielding. The purpose of this study is to design 3D-printed prostheses with topology optimization (TO) for the reconstruction of periacetabular bone tumors and to add porous structures to reduce stress shielding and facilitate integration between prostheses and host bone. Methods: Utilizing patient CT data, we constructed a finite element analysis (FEA) model. Subsequent phases encompassed carrying out TO on the designated area, utilizing the solid isotropic material penalization model (SIMP), and this optimized removal area was replaced with a porous structure. Further analyses included preoperative FEA simulations to comparatively evaluate parameters, including maximum stress, stress distribution, strain energy density (SED), and the relative micromotion of prostheses before and after TO. Furthermore, FEA based on patients' postoperative CT data was conducted again to assess the potential risk of stress shielding subsequent to implantation. Ultimately, preliminary follow-up findings from two patients were documented. Results: In both prostheses, the SED before and after TO increased by 143.61% (from 0.10322 to 0.25145 mJ/mm3) and 35.050% (from 0.30964 to 0.41817 mJ/mm3) respectively, showing significant differences (p < 0.001). The peak stress in the Type II prosthesis decreased by 10.494% (from 77.227 to 69.123 MPa), while there was no significant change in peak stress for the Type I prosthesis. There were no significant changes in stress distribution or the proportion of regions with micromotion less than 28 μm before and after TO for either prosthesis. Postoperative FEA verified results showed that the stress in the pelvis and prostheses remained at relatively low levels. The results of follow-up showed that the patients had successful osseointegration and their MSTS scores at the 12th month after surgery were both 100%. Conclusion: These two types of 3D-printed porous prostheses using TO for periacetabular bone tumor reconstruction offer advantages over traditional prostheses by reducing stress shielding and promoting osseointegration, while maintaining the original stiffness of the prosthesis. Furthermore, in vivo experiments show that these prostheses meet the requirements for daily activities of patients. This study provides a valuable reference for the design of future periacetabular bone tumor reconstruction prostheses.

Biomechanical Analysis of Axial Gradient Porous Dental Implants: A Finite Element Analysis

The porous structure can reduce the elastic modulus of a dental implant and better approximate the elastic characteristics of the material to the alveolar bone. Therefore, it has the potential to alleviate bone stress shielding around the implant. However, natural bone is heterogeneous, and, thus, introducing a porous structure may produce pathological bone stress. Herein, we designed a porous implant with axial gradient variation in porosity to alleviate stress shielding in the cancellous bone while controlling the peak stress value in the cortical bone margin region. The biomechanical distribution characteristics of axial gradient porous implants were studied using a finite element method. The analysis showed that a porous implant with an axial gradient variation in porosity ranging from 55% to 75% was the best structure. Under vertical and oblique loads, the proportion of the area with a stress value within the optimal stress interval at the bone-implant interface (BII) was 40.34% and 34.57%, respectively, which was 99% and 65% higher compared with that of the non-porous implant in the control group. Moreover, the maximum equivalent stress value in the implant with this pore parameter was 64.4 MPa, which was less than 1/7 of its theoretical yield strength. Axial gradient porous implants meet the strength requirements for bone implant applications. They can alleviate stress shielding in cancellous bone without increasing the stress concentration in the cortical bone margin, thereby optimizing the stress distribution pattern at the BII.

Preliminary exploration of the biomechanical properties of three novel cervical porous fusion cages using a finite element study

BACKGROUND

Porous cages are considered a promising alternative to high-density cages because their interconnectivity favours bony ingrowth and appropriate stiffness tuning reduces stress shielding and the risk of cage subsidence.

METHODS

This study proposes three approaches that combine macroscopic topology optimization and micropore design to establish three new types of porous cages by integrating lattices (gyroid, Schwarz, body-centred cubic) with the optimized cage frame. Using these three porous cages along with traditional high-density cages, four ACDF surgical models were developed to compare the mechanical properties of facet articular cartilage, discs, cortical bone, and cages under specific loads.

RESULTS

The facet joints in the porous cage groups had lower contact forces than those in the high-density cage group. The intervertebral discs in all models experienced maximum stress at the C5/6 segment. The stress distribution on the cortical bone surface was more uniform in the porous cage groups, leading to increased average stress values. The gyroid, Schwarz, and BCC cage groups showed higher average stress on the C5 cortical bone. The average stress on the surface of porous cages was higher than that on the surface of high-density cages, with the greatest difference observed under the lateral bending condition. The BCC cage demonstrated favourable mechanical stability.

CONCLUSION

The new porous cervical cages satifies requirements of low rigidity and serve as a favourable biological scaffold for bone ingrowth. This study provides valuable insights for the development of next-generation orthopaedic medical devices.

Interbody Fusion Cage Design Driven by Topology Optimization

OBJECTIVE

We used topology optimization technology to explore the new theory and method of interbody fusion cage design and realized an innovative design of interbody cages.

METHODS

The lumbar spine of a normal healthy volunteer was scanned to perform reverse modeling. Based on the scan data for the L1-L2 segments of the lumbar spine, a three dimensional model was reconstructed to obtain the complete simulation model of the L1-L2 segment. The boundary inversion method was used to obtain approximately isotropic material parameters that can effectively characterize the mechanical behavior of vertebrae, thereby reducing the computational complexity. The topology description function was used to model the clinically used traditional fusion cage to obtain Cage A. The moving morphable void-based topology optimization method was used for the integrated design of size, shape, and topology to obtain the optimized fusion cage, Cage B.

RESULTS

The volume fraction of the bone graft window in Cage B was 74.02%, which was 60.67% higher than that (46.07%) in Cage A. Additionally, the structural strain energy in the design domain of Cage B was 1.48 mJ, which was lower than that of Cage A (satisfying the constraints). The maximum stress in the design domain of Cage B was 5.336 Mpa, which was 35.6% lower than that (8.286 Mpa) of Cage A. In addition, the surface stress distribution of Cage B was more uniform than that of Cage A.

CONCLUSIONS

This study proposed a new innovative design method for interbody fusion cages, which not only provides new insights into the innovative design of interbody fusion cages but may also guide the customized design of interbody fusion cages in different pathological environments.

Optimization of stress distribution of bone-implant interface (BII)

Many studies have found that the threshold of occlusal force tolerated by titanium-based implants is significantly lower than that of natural teeth due to differences in biomechanical mechanisms. Therefore, implants are considered to be susceptible to occlusal trauma. In clinical practice, many implants have shown satisfactory biocompatibility, but the balance between biomechanics and biofunction remains a huge clinical challenge. This paper comprehensively analyzes and summarizes various stress distribution optimization methods to explore strategies for improving the resistance of the implants to adverse stress. Improving stress resistance reduces occlusal trauma and shortens the gap between implants and natural teeth in occlusal function. The study found that: 1) specific implant-abutment connection design can change the force transfer efficiency and force conduction direction of the load at the BII; 2) reasonable implant surface structure and morphological character design can promote osseointegration, maintain alveolar bone height, and reduce the maximum effective stress at the BII; and 3) the elastic modulus of implants matched to surrounding bone tissue can reduce the stress shielding, resulting in a more uniform stress distribution at the BII. This study concluded that the core BII stress distribution optimization lies in increasing the stress distribution area and reducing the local stress peak value at the BII. This improves the biomechanical adaptability of the implants, increasing their long-term survival rate.

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.

Biomechanical analysis of customized cage conforming to the endplate morphology in anterior cervical discectomy fusion: A finite element analysis

In anterior cervical discectomy and fusion (ACDF), an interbody fusion device is an essential implant. An unsuitable interbody fusion device can cause postoperative complications, including subsidence and nonunion. We designed a customized intervertebral fusion device to reduce postoperative complications and validated it by finite element analysis. Herein, we built a non-homogeneous model of the C3-7 cervical spine. Three implant models (customized cage, commercial cage, and bone graft cage) were constructed and placed in the C45 cervical segment after ACDF surgery. The simulated range of motion (ROM), stress at the cage-bone interface, and stress on the cage and implants were compared under different conditions. The commercial cage showed maximum stress peaks at 40.3 MPa and 43.2 MPa in the inferior endplate of C4 and superior endplate of C5 under rotational conditions, higher compared to 29.7 MPa and 26.4 MPa, respectively, in the customized cage. The ROM was not significantly different between the three cages placed after ACDF. The stresses on the commercial cage were higher compared to the other two cages under all conditions. The bone graft in the customized cage was subject to higher stress than the commercial cage under all conditions, particularly lateral bending, wherein the maximum stress was 5.5 MPa. These results showed that a customized cage that better conformed to the vertebral anatomy was promising for reducing the risk of stress shielding and the occurrence of subsidence.

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 comparison of subsidence performance among three modern porous lateral cage designs

BACKGROUND

Cage subsidence remains a major complication after spinal surgery. The goal of this study was to compare the subsidence performance of three modern porous cage designs.

METHODS

Three porous cages were evaluated: a porous titanium cage, a porous polyetheretherketone cage and a truss titanium cage. Mechanical testing was performed for each cage per the American Society for Testing and Materials F2077 and F2267 standards to evaluate cage stiffness and block stiffness, and per a novel clinically relevant dynamic subsidence testing method simulating cyclic spine loading during 3-months postoperatively to evaluate the subsidence displacement.

FINDINGS

The porous polyetheretherketone cage demonstrated the lowest cage stiffness (21.0 ± 1.1 kN/mm), less than half of both titanium cages (truss titanium cage, 49.1 kN/mm; porous titanium cage, 43.6 kN/mm). The block stiffness was greatest for the porous titanium cage (2867.7 ± 105.3 N/mm), followed by the porous polyetheretherketone (2563.4 ± 72.9 N/mm) and truss titanium cages (2213.7 ± 21.8 N/mm). The dynamic subsidence displacement was greatest for the truss titanium cage, which was 1.5 and 2.5 times the subsidence displacement as the porous polyetheretherketone and porous titanium cages respectively.

INTERPRETATIONS

Specific porous cage design plays a crucial role in the cage subsidence performance, to a greater degree than the selection of cage materials. A porous titanium cage with body lattice and microporous endplates significantly outperformed a truss titanium cage with a similar cage stiffness in subsidence performance, and a porous polyetheretherketone cage with half of its stiffness.

Additively manufactured metallic biomaterials

Metal additive manufacturing (AM) has led to an evolution in the design and fabrication of hard tissue substitutes, enabling personalized implants to address each patient's specific needs. In addition, internal pore architectures integrated within additively manufactured scaffolds, have provided an opportunity to further develop and engineer functional implants for better tissue integration, and long-term durability. In this review, the latest advances in different aspects of the design and manufacturing of additively manufactured metallic biomaterials are highlighted. After introducing metal AM processes, biocompatible metals adapted for integration with AM machines are presented. Then, we elaborate on the tools and approaches undertaken for the design of porous scaffold with engineered internal architecture including, topology optimization techniques, as well as unit cell patterns based on lattice networks, and triply periodic minimal surface. Here, the new possibilities brought by the functionally gradient porous structures to meet the conflicting scaffold design requirements are thoroughly discussed. Subsequently, the design constraints and physical characteristics of the additively manufactured constructs are reviewed in terms of input parameters such as design features and AM processing parameters. We assess the proposed applications of additively manufactured implants for regeneration of different tissue types and the efforts made towards their clinical translation. Finally, we conclude the review with the emerging directions and perspectives for further development of AM in the medical industry.

Porous interbody fusion cage design via topology optimization and biomechanical performance analysis

The porous interbody fusion cage could provide space and stable mechanical conditions for postoperative intervertebral bone ingrowth. It is considered to be an important implant in anterior cervical discectomy and internal fixation. In this study, two types of unit cells were designed using topology optimization method and introduced to the interbody fusion cage to improve the biomechanical performances of the cage. Topology optimization under two typically loading conditions was first conducted to obtain two unit cells (O-unit cell and D-unit cell) with the same volume fraction. Porous structures were developed by stacking the obtained unit cells in space, respectively. Then, porous interbody fusion cages were obtained by the Boolean intersection between the global structural layout and the porous structures. Finite element models of cervical spine were created that C5-C6 segment was fused by the designed porous cages. The range of motion (ROM) of the cervical spine, the maximum stress on the cage and the bone graft, and the stress and displacement distributions of the cage were analyzed. The results showed the ROMs of C5-C6 segment in D-unit cell and O-unit cell models were range from 0.14° to 0.25° under different loading conditions; the cage composed of the D-unit cells had a more uniform stress distribution, smaller displacement on cage, a more reasonable internal stress transfer mode (transmission along struts of the unit cell), and higher stress on the internal bone graft (0.617 MPa). In conclusion, the optimized porous cage is a promising candidate for fusion surgery, which would avoid the cage subsidence, and promote the fusion of adjacent endplates.

Subsidence and fusion performance of a 3D-printed porous interbody cage with stress-optimized body lattice and microporous endplates - a comprehensive mechanical and biological analysis

BACKGROUND CONTEXT

Cage subsidence remains a serious complication after spinal fusion surgery. Novel porous designs in the cage body or endplate offer attractive options to improve subsidence and osseointegration performance.

PURPOSE

To elucidate the relative contribution of a porous design in each of the two major domains (body and endplates) to cage stiffness and subsidence performance, using standardized mechanical testing methods, and to analyze the fusion progression via an established ovine interbody fusion model to support the mechanical testing findings.

STUDY DESIGN/SETTING

A comparative preclinical study using standardized mechanical testing and established animal model.

METHODS

To isolate the subsidence performance contributed by each porous cage design feature, namely the stress-optimized body lattice (vs. a solid body) and microporous endplates (vs. smooth endplates), four groups of cages (two-by-two combination of these two features) were tested in: (1) static axial compression of the cage (per ASTM F2077) and (2) static subsidence (per ASTM F2267). To evaluate the progression of fusion, titanium cages were created with a microporous endplate and internal lattice architecture analogous to commercial implants used in subsidence testing and implanted in an endplate-sparing, ovine intervertebral body fusion model.

RESULTS

The cage stiffness was reduced by 16.7% by the porous body lattice, and by 16.6% by the microporous endplates. The porous titanium cage with both porous features showed the lowest stiffness with a value of 40.4±0.3 kN/mm (Mean±SEM) and a block stiffness of 1976.8±27.4 N/mm for subsidence. The body lattice showed no significant impact on the block stiffness (1.4% reduction), while the microporous endplates decreased the block stiffness significantly by 24.9% (p<.0001). All segments implanted with porous titanium cages were deemed rigidly fused by manual palpation, except one at 12 weeks, consistent with robotic ROM testing and radiographic and histologic observations. A reduction in ROM was noted from 12 to 26 weeks (4.1±1.6° to 2.2±1.4° in lateral bending, p<.05; 2.1±0.6° to 1.5±0.3° in axial rotation, p<.05); and 3.3±1.6° to 1.9±1.2° in flexion extension, p=.07). Bone in the available void improved with time in the central aperture (54±35% to 83±13%, p<.05) and porous cage structure (19±26% to 37±21%, p=.15).

CONCLUSIONS

Body lattice and microporous endplates features can effectively reduce the cage stiffness, therefore reducing the risk of stress shielding and promoting early fusion. While body lattice showed no impact on block stiffness and the microporous endplates reduced the block stiffness, a titanium cage with microporous endplates and internal lattice supported bone ingrowth and segmental mechanical stability as early as 12 weeks in ovine interbody fusion.

CLINICAL SIGNIFICANCE

Porous titanium cage architecture can offer an attractive solution to increase the available space for bone ingrowth and bridging to support successful spinal fusion while mitigating risks of increased subsidence.

Mesh Ti6Al4V Material Manufactured by Selective Laser Melting (SLM) as a Promising Intervertebral Fusion Cage

Intervertebral cages made of Ti6Al4V alloy show excellent osteoconductivity, but also higher stiffness, compared to commonly used polyether-ether-ketone (PEEK) materials, that may lead to a stress-shielding effect and implant subsidence. In this study, a metallic intervertebral fusion cage, with improved mechanical behavior, was manufactured by the introduction of a three-dimensional (3D) mesh structure to Ti6Al4V material, using an additive manufacturing method. Then, the mechanical and biological properties of the following were compared: (1) PEEK, with a solid structure, (2) 3D-printed Ti6Al4V, with a solid structure, and (3) 3D-printed Ti6Al4V, with a mesh structure. A load-induced subsidence test demonstrated that the 3D-printed mesh Ti6Al4V cage had significantly lower tendency (by 15%) to subside compared to the PEEK implant. Biological assessment of the samples proved that all tested materials were biocompatible. However, both titanium samples (solid and mesh) were characterized by significantly higher bioactivity, osteoconductivity, and mineralization ability, compared to PEEK. Moreover, osteoblasts revealed stronger adhesion to the surface of the Ti6Al4V samples compared to PEEK material. Thus, it was clearly shown that the 3D-printed mesh Ti6Al4V cage possesses all the features for optimal spinal implant, since it carries low risk of implant subsidence and provides good osseointegration at the bone-implant interface.

Biomechanical changes at the adjacent segments induced by a lordotic porous interbody fusion cage

Biomechanical changes at the adjacent segments after interbody fusion are common instigators of adjacent segment degeneration (ASD). This study aims to investigate how the presence of a lordotic porous cage affects the biomechanical performance of the adjacent segments. A finite element model (FEM) of a lumbar spine implanted with a lordotic cage at L3-L4 was validated by in-vitro testing. The stress distribution on the cage and range of motion (ROM) of L3-L4 were used to assess the stability of the implant. Three angles of cage (0° = non-restoration, 7° = normal restoration and 11° = over-restoration) were modelled with different porosities (0%, 30% and 60%) and evaluated in the motions of flexion, extension, lateral bending and rotation. The ROM, intervertebral disc pressure (IDP) and facet joint force (FJF) were used to evaluate biomechanical changes at the adjacent segments in each model. The results indicated that porous cages produced more uniform stress distribution, but cage porosity did not influence the ROM, IDP and FJF at L2-L3 and L4-L5. Increasing the cage lordotic angle acted to decrease the ROM and IDP, and increase the FJF of L4-L5, but did not alter the ROM of L2-L3. In conclusion, changes in ROM, IDP and FJF at the adjacent segments were mainly influenced by the lordotic angle of the cage and not by the porosity. A larger angle of lordotic cage was shown to reduce the ROM and IDP, and increase the FJF of the lower segment (L4-L5), but had little effect on the ROM of the upper segment (L2-L3).

Can activated titanium interbody cages accelerate or enhance spinal fusion? a review of the literature and a design for clinical trials

While spinal interbody cage options have proliferated in the past decade, relatively little work has been done to explore the comparative potential of biomaterial technologies in promoting stable fusion. Innovations such as micro-etching and nano-architectural designs have shown purported benefits in in vitro studies, but lack clinical data describing their optimal implementation. Here, we critically assess the pre-clinical data supportive of various commercially available interbody cage biomaterial, topographical, and structural designs. We describe in detail the osteointegrative and osteoconductive benefits conferred by these modifications with a focus on polyetheretherketone (PEEK) and titanium (Ti) interbody implants. Further, we describe the rationale and design for two randomized controlled trials, which aim to address the paucity of clinical data available by comparing interbody fusion outcomes between either PEEK or activated Ti lumbar interbody cages. Utilizing dual-energy computed tomography (DECT), these studies will evaluate the relative implant-bone integration and fusion rates achieved by either micro-etched Ti or standard PEEK interbody devices. Taken together, greater understanding of the relative osseointegration profile at the implant-bone interface of cages with distinct topographies will be crucial in guiding the rational design of further studies and innovations.

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.