Biomechanical optimization of the far cortical locking technique for early healing of distal femur fractures

Biomechanical testing of a computationally optimized far cortical locking plate versus traditional implants for distal femur fracture repair

BACKGROUND

This study experimentally validated a computationally optimized screw number and screw distribution far cortical locking distal femur fracture plate and compared the results to traditional implants.

METHODS

24 artificial femurs were osteotomized with a 10 mm fracture gap 60 mm proximal to the intercondylar notch. Three fixation constructs were used. (i) Standard locking plates secured with three far cortical locking screws inserted according to a previously optimized distribution in the femur shaft (n = 8). (ii) Standard locking plates secured with four standard locking screws inserted in alternating plate holes in the femur shaft (n = 8). (iii) Retrograde intramedullary nail secured proximally with one anterior-posterior screw and distally with two oblique screws (n = 8). Axial hip forces (700 and 2800 N) were applied while measuring axial interfragmentary motion, shear interfragmentary motion, and overall stiffness.

FINDINGS

Experimental far cortical locking plate results compared well to published computational findings. Far cortical locking femurs contained the highest axial motion within the potential ideal range of 0.2-1 mm and a sheer-to-axial motion ratio < 1.6 at toe-touch weight-bearing (700 N). At full weight-bearing (2800 N), Standard locking-plated femurs had the only axial motion within 0.2-1 mm but had an excess shear-to-axial motion ratio. Nail-implanted femurs underperformed at both forces.

INTERPRETATION

For toe-touch weight-bearing, the far cortical locking construct provided optimal biomechanics to allow moderate motion, which has been suggested to encourage early callus formation. Conversely, at full weight-bearing, the standard locking construct offered the biomechanical advantage on fracture motion.

IFM calculator: An algorithm for interfragmentary motion calculation in finite element analysis

BACKGROUND

Interfragmentary motion (IFM) is a complex state that significantly impacts the healing process of fractures following implant placement. It is crucial to fully consider the IFM state after implantation in the design and biomechanical testing of implants. However, current finite element analysis software lacks direct tools for calculating IFM, and existing IFM tools do not offer a comprehensive solution in terms of accuracy, functionality, and visualization.

METHODS

In our study, we developed a Python-based algorithm for calculating IFM that addresses limitations. Our algorithm automatically calculated IFM distances, sliding distances, gaps, as well as the angles and rotation of the two fracture surfaces using all nodes on both sides of the fracture ends. Researchers could input data and selected desired parameters in the interface. The algorithm then performed the necessary calculations and presented the results in a clear and concise manner. The algorithm also provided comprehensive data export capabilities, allowing researchers to customize analyses based on specific needs.To provide a more intuitive demonstration of the calculation process and usage of IFM-Cal, we conducted simulations in Ansys using two rectangular blocks to compare the accuracy and function of three different methods (Point based method, contact tool and IFM-Cal).

RESULTS

The point-based method and the contact tool could not accurately calculate IFA, while IFM-Cal could provide a comprehensive evaluation of IFA. In simulation 1, the IFM distances calculated using the point sampling method, contact tool, and IFM-Cal were 2.00 mm, 3.15 mm, and 2.00 mm, respectively. In simulation 2, both the point sampling method and contact tool failed to calculate the interfragmentary angle (IFA), while the IFM-Cal algorithm estimated an angle of -7.87°, which had a small error compared to the ground-truth value of 7.9°.

CONCLUSION

We have developed an algorithm for computing IFM which can be utilized in finite element analysis and biomechanical experiments. By conducting comparative simulations with other existing algorithms, we have demonstrated the superior accuracy and expanded evaluation capabilities of our algorithm.

Biomechanical effects of different loads and constraints on finite element modeling of the humerus

Currently, there is no established finite element (FE) method to apply physiologically realistic loads and constraints to the humerus. This FE study showed that 2 'simple' methods involving direct head loads, no head constraints, and rigid elbow or mid-length constraints created excessive stresses and bending. However, 2 'intermediate' methods involving direct head loads, but flexible head and elbow constraints, produced lower stresses and bending. Also, 2 'complex' methods involving muscles to generate head loads, plus flexible head and elbow constraints, generated the lowest stresses and moderate bending. This has implications for FE modeling research on intact and implanted humeri.

Does Far Cortical Locking Improve Fracture Healing in Distal Femur Fractures: A Randomised, Controlled, Prospective Multicentre Study

(1) Background: Bone healing is influenced by various mechanical factors, such as stability, interfragmentary motion, strain rate, and direction of loading. Far cortical locking (FCL) is a novel screw design that promotes bone healing through controlled fracture motion. (2) Methods: This study compared the outcome of distal femur fractures treated with FCL or SL (standard locking) screws and an NCB plate in a randomised controlled prospective multicentre trial. The radiographic union scale (RUST) and healing time was used to quantify bone healing on follow-up imaging. (3) Results: The study included 21 patients with distal femur fractures, 7 treated with SL and 14 treated with FCL screws. The mean working length for patients with SL screws was 6.1, whereas for FCL screws, it was 3.9. The mean RUST score at 6 months post fracture was 8.0 for patients with SL plates and 7.3 for patients with FCL plates (p value > 0.05). The mean healing time was 6.5 months for patients with SL plates and 9.9 months for patients with FCL plates (p value < 0.05). (4) Conclusions: Fractures fixed with SL plates had longer working lengths and faster healing times when compared to FCL constructs, suggesting that an adequate working length is important for fracture healing regardless of screw choice.

Influence of knee flexion on early femoral fracture healing: A combined analysis of musculoskeletal dynamics and finite elements

BACKGROUND AND OBJECTIVES

Knee flexion causes a certain amount of misalignment and relative movement of the fractured ends of the femur fracture, and if the flexion angle is too large it will affect the stability of the fracture and the healing process, making it challenging to design a safe range of flexion. However, due to a lack of basic understanding of the effect of knee flexion on the mechanical environment at the fracture site, clinicians are often unable to provide an objective and safe range of motion in flexion based on subjective experience. The aim of this study was to evaluate the effect of knee flexion on plate and fracture healing using finite element analysis (FEA).

METHODS

A human musculoskeletal model was constructed based on CT scan data, and the mechanical properties of the fracture site were changed by adjusting the knee flexion angle. The joint forces, muscle forces and moments acting on the femur were obtained by inverse dynamics analysis, and the biomechanical properties of the fracture-plate system were analyzed using finite elements. A finite element model of the fracture-plate system without muscle loading was also constructed. The effect of knee flexion on the safety of plate fixation and fracture healing was evaluated in terms of the biomechanical properties of the plate and the interfragmentary motion of the fracture.

RESULTS

As the knee flexion angle increases, the von Mises stress of the locked compression plate (LCP) first increases, then decreases, then increases again. The deformation from compression bending to tension twisting occurs simultaneously. At 30° of flexion, shear interfragmentary motion (SIM) was dominant and inhibited fracture healing; at more than 45° of flexion, the plate was twisted and deformed to the lateral side of the body, and the fracture site underwent greater misalignment and relative motion, with destructive effects on bone scabs and healing tissues. If muscle loading is not taken into account, the plate will undergo predominantly bending deformation and will overestimate the interfragmentary strain in the far and near cortex.

CONCLUSIONS

Knee flexion causes the plate to deform from compression bending to extension and torsion, which has an important impact on the safety and healing process of the fracture, and this study provides a biomechanical basis to guide the clinician in the post-operative rehabilitation of femoral fractures in the clinical setting.

Biomechanical design optimization of distal femur locked plates: A review

Clinical findings, manufacturer instructions, and surgeon's preferences often dictate the implantation of distal femur locked plates (DFLPs), but healing problems and implant failures still persist. Also, most biomechanical researchers compare a particular DFLP configuration to implants like plates and nails. However, this begs the question: Is this specific DFLP configuration biomechanically optimal to encourage early callus formation, reduce bone and implant failure, and minimize bone "stress shielding"? Consequently, it is crucial to optimize, or characterize, the biomechanical performance (stiffness, strength, fracture micro-motion, bone stress, plate stress) of DFLPs influenced by plate variables (geometry, position, material) and screw variables (distribution, size, number, angle, material). Thus, this article reviews 20 years of biomechanical design optimization studies on DFLPs. As such, Google Scholar and PubMed websites were searched for articles in English published since 2000 using the terms "distal femur plates" or "supracondylar femur plates" plus "biomechanics/biomechanical" and "locked/locking," followed by searching article reference lists. Key numerical outcomes and common trends were identified, such as: (a) plate cross-sectional area moment of inertia can be enlarged to lower plate stress at the fracture; (b) plate material has a larger influence on plate stress than plate thickness, buttress screws, and inserts for empty plate holes; (c) screw distribution has a major influence on fracture micro-motion, etc. Recommendations for future work and clinical implications are then provided, such as: (a) simultaneously optimizing fracture micro-motion for early healing, reducing bone and implant stresses to prevent re-injury, lowering "stress shielding" to avoid bone resorption, and ensuring adequate fatigue life; (b) examining alternate non-metallic materials for plates and screws; (c) assessing the influence of condylar screw number, distribution, and angulation, etc. This information can benefit biomedical engineers in designing or evaluating DFLPs, as well as orthopedic surgeons in choosing the best DFLPs for their patients.

Dual plating for fixation failure of the distal femur: Finite element analysis and a clinical series

BACKGROUND

The optimal technique for managing distal femur fixation failure remains inconclusive. The author studied the efficacy of a combined proximal humerus locking compression plate (LCP-PH) and 3.5 mm reconstruction plate (LCP-RP) by finite element (FE) analysis and retrospectively described the clinical outcomes of the present technique in such difficult circumstances.

METHODS

Biomechanical study setting included FE models of the distal femur with remaining holes from previous distal femur LCP (LCP-DF) fixation stabilized with three different constructs i.e., LCP-DF alone, LCP-DF-and-LCP-RP, as well as LCP-PH-and-LCP-RP. All settings were analyzed by using FE under physiological loads. Regarding the clinical series, the outcomes of 8 LCP-DF fixation failures operated on by the present technique were retrospectively reviewed.

RESULTS

High Implant stress of 911.2 MPa and elastic strain at fracture site of 200.8 µɛ were found when stabilized with LCP-DF. The constructs of LCP-DF-and-LCP-RP, and LCP-PH-and-LCP-RP presented lower implant stress compared to LCP-DF, 511.5, and 617.5 MPa, respectively. The elastic strain of both dual plating constructs was also 4-5 times lower than LCP-DF and differed from each other by approximately 10 µɛ. Regarding the clinical series, bony consolidation was achieved in all cases with a mean duration of 28.5 weeks (range 24-36). An average ROM of the affected knee was 115° (range 105-140). Regarding the KSS, 1 was determined to be excellent and 7 to be good.

CONCLUSION

By the biomechanical analysis and the clinical results, the construct of LCP-PH-and-LCP-RP could be an effective technique for revision surgery of LCP-DF fixation failure.

Optimal design and biomechanical analysis of sandwich composite metal locking screws for far cortical locking constructs

In the interests of more flexible and less stiff bridge constructs to stimulate bone healing, the technique of far cortical locking has been designed to improve locked plating constructs in terms of stress concentration, stress shielding, and inhibition of issues around fracture healing. However, far cortical locking screws currently lack objective designs and anti-fatigue designs. This study investigates an optimization algorithm to form a special locking screw composed of various metals, which can theoretically achieve the maintenance of the excellent mechanical properties of far cortical locking constructs in terms of fracture internal fixation, while maintaining the biomechanical safety and fatigue resistance of the structure. The numerical results of our study indicate that the maximum von Mises stress of the optimized construct is less than the allowable stress of the material under each working condition while still achieving sufficient parallel interfragmentary motion. Numerical analysis of high cycle fatigue indicates that the optimized construct increases the safety factor to five. A high cycle fatigue test and defect analysis indicates that the sandwich locking constructs have better fatigue resistance. We conclude that the sandwich locking construct theoretically maintains its biomechanical safety and fatigue resistance while also maintaining excellent mechanical properties for fracture internal fixation.

A 20-Year Review of Biomechanical Experimental Studies on Spine Implants Used for Percutaneous Surgical Repair of Vertebral Compression Fractures

A vertebral compression fracture (VCF) is an injury to a vertebra of the spine affecting the cortical walls and/or middle cancellous section. The most common risk factor for a VCF is osteoporosis, thus predisposing the elderly and postmenopausal women to this injury. Clinical consequences include loss of vertebral height, kyphotic deformity, altered stance, back pain, reduced mobility, reduced abdominal space, and reduced thoracic space, as well as early mortality. To restore vertebral mechanical stability, overall spine function, and patient quality of life, the original percutaneous surgical intervention has been vertebroplasty, whereby bone cement is injected into the affected vertebra. Because vertebroplasty cannot fully restore vertebral height, newer surgical techniques have been developed, such as kyphoplasty, stents, jacks, coils, and cubes. But, relatively few studies have experimentally assessed the biomechanical performance of these newer procedures. This article reviews over 20 years of scientific literature that has experimentally evaluated the biomechanics of percutaneous VCF repair methods. Specifically, this article describes the basic operating principles of the repair methods, the study protocols used to experimentally assess their biomechanical performance, and the actual biomechanical data measured, as well as giving a number of recommendations for future research directions.

Finite Element Analysis of Fracture Fixation

PURPOSE OF REVIEW

Fracture fixation aims to provide stability and promote healing, but remains challenging in unstable and osteoporotic fractures with increased risk of construct failure and nonunion. The first part of this article reviews the clinical motivation behind finite element analysis of fracture fixation, its strengths and weaknesses, how models are developed and validated, and how outputs are typically interpreted. The second part reviews recent modeling studies of the femur and proximal humerus, areas with particular relevance to fragility fractures.

RECENT FINDINGS

There is some consensus in the literature around how certain modeling aspects are pragmatically formulated, including bone and implant geometries, meshing, material properties, interactions, and loads and boundary conditions. Studies most often focus on predicted implant stress, bone strain surrounding screws, or interfragmentary displacements. However, most models are not rigorously validated. With refined modeling methods, improved validation efforts, and large-scale systematic analyses, finite element analysis is poised to advance the understanding of fracture fixation failure, enable optimization of implant designs, and improve surgical guidance.