Effect of cutting flute design on cortical bone screw insertion torque and pullout strength

3D printed patient-specific fixation plates for the treatment of slipped capital femoral epiphysis: Topology optimization vs. conventional design

Orthopedic plates are commonly used after osteotomies for temporary fixation of bones. Patient-specific plates have recently emerged as a promising fixation device. However, it is unclear how various strategies used for the design of such plates perform in comparison with each other. Here, we compare the biomechanical performance of 3D printed patient-specific bone plates designed using conventional computer-aided design (CAD) techniques with those designed with the help of topology optimization (TO) algorithms, focusing on cases involving slipped capital femoral epiphysis (SCFE). We established a biomechanical testing protocol to experimentally assess the performance of the designed plates while measuring the full-field strain using digital image correlation. We also created an experimentally validated finite element model to analyze the performance of the plates under physiologically relevant loading conditions. The results indicated that the TO construct exhibited higher ultimate load and biomechanical performance as compared to the CAD construct, suggesting that TO is a viable approach for the design of such patient-specific bone plates. The TO plate also distributed stress more evenly over the screws, likely resulting in more durable constructs and improved anatomical conformity while reducing the risk of screw and plate failure during cyclic loading. Although differences existed between finite element analysis and experimental testing, this study demonstrated that finite element modelling can be used as a reliable method for evaluating and optimizing plates for SCFE patients. In addition to enhancing the mechanical performance of patient-specific fixation plates, the utilization of TO in plate design may also improve the surgical outcome and decrease the recovery time by reducing the plate and incision sizes.

Biomechanical comparison of compact versus standard flute drill bits, and interlocking versus buttress thread self-tapping cortical bone screws in cadaveric equine third metacarpal condyle

OBJECTIVES

To compare (1) performance of compact versus standard flute drill bits, (2) screw insertion properties and (3) pullout variables between interlocking thread (ITS) and buttress thread (BTS) self-tapping screws in third metacarpi.

STUDY DESIGN

In vitro experimental study.

SAMPLE POPULATION

Paired third metacarpi from 11 Thoroughbreds aged 2-4 years.

METHODS

Screws were inserted into the lateral condylar fossae following bone preparation using the respective drill bit for each screw type. Screw pullout was achieved using a mechanical testing system. Density and porosity of bone surrounding screw holes was measured with microcomputed tomography following each pullout test. Drilling, screw insertion and pullout variables were compared between drill bit and screw types using repeated measures ANOVA. Linear regression analyses were used to characterize relationships between bone tissue properties and drill bit and screw outcomes.

RESULTS

Maximum torque power spectral density (PSD) was lower for compact flute drill bits. Insertion torque was 50% higher for ITS. BTS had 33% greater preyield stiffness and 7% greater mean yield force. Bone tissue properties affected measured variables similarly for both screw and drill bit types.

CONCLUSIONS

Lower torque PSD may increase durability of the compact flute drill bit. ITS had greater insertional torque, which may reflect greater bone engagement. BTS had greater resistance to axial pullout forces.

CLINICAL SIGNIFICANCE

Metacarpal bone provides a simple model for comparison of drill bit and screw designs. Use of ITS to repair equine fractures subject to predominantly tensile forces is not justified based on the results of this study.

Effect of screw insertion angle and speed on the incidence of transcortical fracture development in a canine tibial diaphyseal model

OBJECTIVE

To assess the incidence of transcortical fracture (TCF) development based on screw insertion angle and screw insertion speed.

STUDY DESIGN

Cadaveric experimental study.

SAMPLE POPULATION

Sixty-six canine tibiae.

METHODS

Sixty-six cadaveric tibiae were randomly assigned to one of six groups that varied based on screw insertion angle relative to the pilot hole (0, 5, or 10°) and screw insertion speed (650 or 1350 revolutions per minute [rpm]). Each tibia was mounted in a custom jig. Locking self-tapping screws (3.5 mm) were inserted at varying speeds and insertion angles, based on group assignment. Orthogonal radiographs were evaluated for TCFs. Fisher's exact tests with a Bonferroni correction were performed to evaluate differences in the frequency of TCF between groups.

RESULTS

In Group A (0°/650 rpm: control), a 0% TCF rate was observed (n = 0/80). Group B (5°/650 rpm) had a 3.75% TCF rate (n = 3/80). Group C (10°/650 rpm) had a 12.5% TCF rate (n = 10/80). Group D (10°/hand insertion) had a 3.75% TCF rate (n = 3/80). Group E (10°/1350 rpm) had a 17.5% TCF rate (n = 14/80). Group F (0°/1350 rpm) had a 0% TCF rate (n = 0/80). Groups C and E had the highest TCF rates with a difference in TCF rates observed between the control group and Group C (p = .001) and between the control group and Group E (p < .001).

CONCLUSION

Increased screw insertion angle and insertion speed appear to be predisposing factors for TCF development in cadaveric bone.

CLINICAL SIGNIFICANCE

Ensuring screw insertion is coaxial with the pilot hole and using slower screw insertion speeds may help reduce the risk of TCF development.

Cutting Flute and Thread Design on Self-Tapping Pedicle Screws Influence the Insertion Torque and Pullout Strength

Self-tapping screws are commonly used in trauma and maxillofacial surgery and are increasingly used for pedicle screw insertions. In order to evaluate how the quantity and length of cutting flutes on self-tapping pedicle screws affect the insertion torque and pullout strength, eight different self-tapping pedicle screw designs were evaluated. All screws had a threaded length of 35 mm and featured variations in the number of leads, as well as the length and quantity of cutting flutes. Five samples of each design were inserted into pre-drilled, untapped holes (ø2.7 mm, length 35 mm) in sawbone blocks of density 20 PCF. The insertion torque and pullout strength were measured according to ASTM F543. The results showed that screws with a longer cutting flute of 9.5 mm had a lower mean maximum insertion torque than screws with shorter 2.9 mm cutting flutes. Pedicle screws with a double-lead thread design had a greater insertion torque than their single-lead counterparts, and the use of three cutting flutes produced a lower torque than two cutting flutes. The results demonstrated a greater pullout strength in screws with a single-lead thread rather than a double-lead, three cutting flutes instead of two, and a longer length for the cutting flute. In conclusion, to provide immediate stability and reduce the surgical insertion time, a single-lead, self-tapping pedicle screw incorporating three long cutting flutes is recommended because of the significantly greater pullout strength. This design could also reduce the risk of implant loosening in comparison to double-lead, self-tapping pedicle screw designs.

Drilling Capability of Orthodontic Miniscrews: In Vitro Study

The aims of this study were to assess the values and mechanical properties of insertion torque (IT) of steel miniscrews inserted in artificial bone blocks (Sawbones, Pacific Research Laboratories, Vashon, WA, USA) with different bone densities and to detect any scratches on the surface of the miniscrews after insertion. Forty self-drilling miniscrews (Leone S.p.A. ø 1.75 mm, L 8 mm) have been inserted into bone blocks that mimic different stability conditions (density: 20 PCF-pounds per cubic foot, 40 PCF, and 30 + 50 PCF with 2 mm and 4 mm of cortical bone). Before insertion and after removal, all miniscrews were inspected with a stereomicroscope 5x and a SEM to detect potential microscopic cracks. Using an electronic surgical motor (W&H Dentalwerk Bürmoos GmbH, Werner Bader Str. 1, 5111 Bürmoos, Austria), the maximum insertion torque value was registered. Stereomicroscope and SEM examination did not indicate any morphological and surface structural changes to the miniscrews, irrespective of the bone density they were inserted into. The findings showed that IT increased significantly with increasing bone density. In each artificial bone block, morphostructural analysis demonstrated the adequate mechanical properties of the self-drilling miniscrews. IT measurements indicated torque values between 6 and 10 Ncm for blocks with a density of 30 + 50 PCF, whereas the suggested values are between 5 and 10 Ncm.

MULTI-OBJECTIVE OPTIMIZATION FOR SURGICAL DRILLING OF HUMAN FEMURS: A METHODOLOGY FOR BETTER PULL-OUT STRENGTH OF FIXATION USING TAGUCHI METHOD BASED ON MEMBERSHIP FUNCTION

Drilling through bone is one of the common cutting processes involved in many of the orthopedic surgeries. In bone drilling, spindle speed, feed rate, diameter of the drill bit, drill bit geometry and method of cooling are the important parameters to influence the in-situ temperature, drill thrust force and quality characteristics of the drilled hole. Because of the selection of inappropriate drilling parameters, uncontrolled large drilling forces, continuous increase in temperature and mechanical damage to the local host bone were observed. As these adverse effects lead to poor bone–implant contact and often a revision surgery, performing a surgical drilling with optimal parameters is essential to succeed in the surgical procedure. It was observed that in addition to the variations in apparent bone density, the orientation of osteons influences the drilling thrust force and temperature in bone drilling. Ten adult cadaveric human femurs from the age group of 32–65 years were considered and drilling experiments were conducted on proximal-diaphysis, mid-diaphysis and distal-diaphysis regions in the longitudinal, radial and circumferential directions. Bone drilling with different spindle speeds (500, 1000 and 1500[Formula: see text]rpm), feed rates (40, 60 and 80[Formula: see text]mm/min), and apparent density in the range of 0.98[Formula: see text]g/cm3 to 1.98[Formula: see text]g/cm3 was investigated in this work using a 3.20[Formula: see text]mm diameter surgical drill-bit. The generation of in-situ temperature as well as thrust force at each target location was measured using [Formula: see text]-type thermocouple and Kistler[Formula: see text] dynamometer, respectively. Taguchi method based on membership function was used to optimize the drilling process. Then the efficacy of the method in reducing the in-situ temperature and thrust force, and quality of the drilled hole in respect of anatomical region and drilling direction was investigated using pull-out strength of the bone screws. Results revealed that the optimal parameters obtained from the Taguchi method based on membership function could simultaneously minimize the temperature as well as thrust force in bone drilling. The proposed method can be adopted to minimize the temperature and thrust force, and choose the best location nearest to the defect site for strong implant fixation by using CT datasets of the patient as the only input.

A comparative study of tapped and untapped pilot holes for bicortical orthopedic screws – 3D finite element analysis with an experimental test

The aim of this study was to compare the screw-to-bone fixation strength of two insertion techniques: self-tapping screw (STS) and non-self-tapping screw (NSTS). Finite element analysis (FEA) was used for the comparison by featuring three tests (insertion, pull-out and shear) in a human tibia bone model. A non-linear material behavior with ductile damage properties was chosen for the modeling. To validate the numerical models, experimental insertion and pull-out tests were carried out using a synthetic bone. The experimental and numerical results of pull-out tests correlated well. Thread forming was successfully simulated during the insertion process of STS and NSTS. It is demonstrated that the STS generates higher insertion torque, induces a higher amount of stress after the insertion process and relatively more strength under the pull-out and shear tests than the NSTS. However, the NSTS induces more stiffness under the two tests (pull-out and shear) and less damage to the screw-bone interface compared to the STS. It is concluded that the use of STS ensures tighter bony contact and enables higher pull-out strength; however, the use of NSTS improves the stiffness of the fixation and induces less damage to the cortical bone-screw fixation and thus minimum risk is obtained in terms of bone necrosis.

Distribution and amount of stresses caused by insertion or removal of orthodontic miniscrews into the maxillary bone: A finite element analysis

OBJECTIVE

Initial stability of miniscrews is an important factor in their success as orthodontic anchorages. One of the factors affecting this stability is the stresses exerted to the bone by the screw. Since the distribution and extent of stresses and strains produced during insertion or removal of miniscrews had not been measured before, this study used finite element analysis (FEA) to measure these parameters in tapered versus cylindrical screws with or without pilot sockets.

MATERIALS AND METHODS

An FEA model of maxilla, pilot hole, and tapered/cylindrical miniscrews were created from 875 CT scan data. The bone cortex was considered 2mm thick. The cancellous bone was reconstructed below the cortical bone. Miniscrews were modelled on the basis of commercial titanium tapered and cylindrical miniscrews (1.6mm wide, 8mm long). The diameter and length of the guiding hole were considered to be 1.1 and 1.5mm, respectively. The miniscrews were inserted (and removed) between the maxillary second premolar and first molar. Stress/strain produced in the bones or screws were measured.

RESULTS

During screw insertion, in all setups, the highest stress existed within both the bone and screw, when the screw was in the cortical bone; after insertion into the cancellous bone, the stress suddenly dropped. In cylindrical screws, the highest amount of stress was distributed around the neck which was used for screw driving. In tapered screws, the stress was mostly distributed around the front one-third of the screw. During screw removal, the results of four setups were rather similar with stresses concentrated around screw necks, in the depth of the screw hole, and around the bone surface. The greatest bone stress during insertion was caused by the pilot-less tapered screw (10.18MPa) and the lowest stress was exerted by a pilot-less cylindrical screw (0.74MPa).

CONCLUSION

Most of the stress and strain is tolerated by the cortical bone and not the cancellous one. Using cylindrical miniscrews might be more bone-friendly. However, all cases had stresses below tolerable thresholds, and hence are safe.

Development and initial validation of a novel smoothed-particle hydrodynamics-based simulation model of trabecular bone penetration by metallic implants

A novel computational model of implant migration in trabecular bone was developed using smoothed-particle hydrodynamics (SPH), and an initial validation was performed via correlation with experimental data. Six fresh-frozen human cadaveric specimens measuring 10 × 10 × 20 mm were extracted from the proximal femurs of female donors (mean age of 82 years, range 75-90, BV/TV ratios between 17.88% and 30.49%). These specimens were then penetrated under axial loading to a depth of 10 mm with 5 mm diameter cylindrical indenters bearing either flat or sharp/conical tip designs similar to blunt and self-tapping cancellous screws, assigned in a random manner. SPH models were constructed based on microCT scans (17.33 µm) of the cadaveric specimens. Two initial specimens were used for calibration of material model parameters. The remaining four specimens were then simulated in silico using identical material model parameters. Peak forces varied between 92.0 and 365.0 N in the experiments, and 115.5-352.2 N in the SPH simulations. The concordance correlation coefficient between experimental and simulated pairs was 0.888, with a 95%CI of 0.8832-0.8926, a Pearson ρ (precision) value of 0.9396, and a bias correction factor Cb (accuracy) value of 0.945. Patterns of bone compaction were qualitatively similar; both experimental and simulated flat-tipped indenters produced dense regions of compacted material adjacent to the advancing face of the indenter, while sharp-tipped indenters deposited compacted material along their peripheries. Simulations based on SPH can produce accurate predictions of trabecular bone penetration that are useful for characterizing implant performance under high-strain loading conditions. © 2017 Orthopaedic Research Society. Published by Wiley Periodicals, Inc. J Orthop Res 36:1114-1123, 2018.

Theoretical prediction of pullout strengths for dental and orthopaedic screws with conical profile and buttress threads

BACKGROUND AND OBJECTIVE

The pullout strength of a screw is an indicator of how secure bone fragments are being held in place. Such bone-purchasing ability is sensitive to bone quality, thread design, and the pilot hole, and is often evaluated by experimental and numerical methods. Historically, there are some mathematical formulae to simulate the screw withdrawal from the synthetic bone. There are great variations in screw specifications. However, extensive investigation of the correlation between experimental and analytical results has not been reported in literature.

METHODS

Referring to the literature formulae, this study aims to evaluate the differences in the calculated pullout strengths. The pullout tests of the surgical screws are measured and the sawbone is used as the testing block. The absolute errors and correlation coefficients of the experimental and analytical results are calculated as the comparison baselines of the formulae.

RESULTS

The absolute error of the dental, traumatic, and spinal groups are 21.7%, 95.5%, and 37.0%, respectively. For the screws with a conical profile and/or tiny threads, the calculated and measured results are not well correlated. The formulae are not accurate indicators of the pullout strengths of the screws where the design parameters are slightly varied. However, the experimental and numerical results are highly correlated for the cylindrical screws. The pullout strength of a conical screw is higher than that of its counterpart, but all formulae consistently predict the opposite results. In general, the bony purchase of the buttress threads is securer than that of the symmetric thread.

CONCLUSIONS

An absolute error of up to 51.4% indicates the theoretical results cannot predict the actual value of the pullout strength. Only thread diameter, pitch, and depth are considered in the investigated formulae. The thread profile and shape should be formulated to modify the slippage mechanism at the bone-screw interfaces and simulate the strength change in the squeezed bones, especially for the conical screw.

Interfacial sliding properties of bone screw materials and their effect on screw fixation strength

BACKGROUND

This study examined the effect of interfacial sliding and test material properties on the fixation strength and insertional properties of self-tapping bone screws. Various substitute materials (polyacetal [POM], poly(methyl methacrylate) [PMMA] and E-glass-filled Epoxy [Sawbones®]) for human bone were evaluated, and the results were compared with the findings for cadaver bone.


METHODS

Initial coefficient of friction (CoF) of the screw material stainless steel AISI316 was tested using a pin-on-disk apparatus, and the screws were exposed to pullout tests after insertion torque tests. The effect of a smooth diamond-like carbon (DLC) coating was studied by applying the coating on both CoF test balls and bone screws.


RESULTS

Mechanical properties of test blocks strongly correlated to both pullout strength and insertion torque of the screws: for noncoated 2.7-mm screws, tensile strength correlated to pullout strength and insertion torque, with Pearson correlation coefficients r=0.977 and r=0.738, respectively. In contrast, CoF correlated strongly to screw insertion torque but not to pullout strength in bone substitute materials (for noncoated 2.7-mm screws, r=0.652 and r=0.248, respectively). There were no significant differences in CoF using noncoated and DLC-coated screw materials against bone substitutes.


CONCLUSIONS

Proper materials for in vitro testing help in evaluating the biomechanics of the implants in advance. However, choosing the material needs attention, as their ability to model human bone depends on test type.

Incidence of transcortical tibial fractures with self-tapping and non-self-tapping screws in a canine TPLO model

OBJECTIVE

To compare the incidence of radiographically apparent transcortical diaphyseal tibial fractures between self-tapping screws (STS) and non-self-tapping screws (NSTS) in a canine tibial plateau leveling osteotomy (TPLO) model.

STUDY DESIGN

Case series.

ANIMALS

Dogs (n = 106) that had TPLO.

METHODS

NSTS (n = 107), STS titanium (n = 104), or STS stainless steel (n = 105) screws were used for TPLO. Effect of STS and NSTS were compared by reviewing postoperative craniocaudal and lateral radiographic projections taken immediately after TPLO. Three screws distal to the tibial osteotomy served as the in vivo model for canine cortical bone. A transcortical fracture was defined as the presence of a saucer-shaped radiolucent defect on the periosteal surface of the trans-cortex surrounding the screw and the presence of radiopaque material (bone) separate from the transcortical periosteal surface. The effect of screw type and STS material (stainless steel or titanium) on the incidence of transcortical fractures was evaluated.

RESULTS

STS had a significantly higher (P = .006) incidence of transcortical fractures (18.0%) compared with NSTS (0.8%). The effect of STS material on the incidence of transcortical fractures was not significant (P = .485). No cis-cortical factures were identified.

CONCLUSIONS

We suspect the increased incidence of transcortical fractures with STS is because of the shorter cutting flutes as compared with those of a tap used with a NSTS.

Correlation of the experimental and numerical results for the holding power of dental, traumatic, and spinal screws

The holding power of the bone-screw interfaces is one of the key factors in the clinical performance of screw design. The value of the holding power can be experimentally measured by pullout tests. Historically, some researchers have used the finite-element method to simulate the holding power of the different screws. Among them, however, the assumed displacement of the screw withdrawal is unreasonably small (about 0.005-1.0 mm). In addition, the chosen numerical indices are quite different, including maximum stress, strain energy, and reaction force. This study systematically uses dental, traumatic, and spinal screws to experimentally measure and numerically simulate their bone-purchasing ability within the synthetic bone. The testing results (pullout displacement and holding power) and numerical indices (maximum stress, total strain energy, and reaction forces) are chosen to calculate their correlation coefficients. The pullout displacement is divided into five regions from initial to final withdrawal. The experimental results demonstrate that the pullout displacement consistently occurs at the final region (0.6-1.6 mm) and is significantly higher than the assumed value of the literature studies. For all screw groups, the measured holding power within the initial region is not highly or even negatively correlated with the experimental and numerical results within the final region. The observation from the simulative results shows the maximum stress only reflects the loads concentrated at some local site(s) and is the least correlated to the measured holding power. Comparatively, both energy and force are more global indices to correlate with the gross failure at the bone-screw interfaces. However, the energy index is not suitable for the screw groups with rather tiny threads compared with the other specifications. In conclusion, the underestimated displacement leads to erroneous results in the screw-pullout simulation. Among three numerical indices the reaction-force is the optimal index for the screw-pullout problem.

The treatment of periprosthetic fractures with locking plates: effect of drill and screw type on cement mantles: a biomechanical analysis

INTRODUCTION

Periprosthetic fractures after cemented hip replacement are a challenging problem to manage. Biomechanical studies have suggested the benefit of using locking screws for plate fixation, but there are concerns whether screws damage the cement mantle and promote crack propagation leading to construct failure.

METHOD

In this biomechanical study, different screw types were implanted into the cement mantle after pre-drilling holes of different sizes, in unicortical and bicortical configuration. The presence of cracks and the pull-out resistance of these screws were then evaluated.

RESULTS

No unicortical screw induced cracks. Screws with a shortened tip, smaller flutes and double threads were significantly better for pull-out resistance. Bicortical screws were associated with a risk of local cement mantle damage, but also with a significantly greater holding power. By increasing the drill diameter, the onset of cracks decreased, but so does the pull-out resistance.

Pitch and longitudinal fluting effects on the primary stability of miniscrew implants

OBJECTIVE

To test the hypotheses that pitch and fluting have no effect on the primary stability of miniscrew implants (MSIs).

MATERIALS AND METHODS

Maximum placement torque and pullout strength of experimental MSIs were compared with those of control MSIs with the use of synthetic and cadaver bone. MSIs with 1.00 mm pitch were compared with those with 1.25 mm and 0.75 mm pitch; MSIs with three longitudinal flutes were compared with the same MSIs without flutes. A total of 60 MSIs (15 of each design) were evaluated with synthetic bone; a split-mouth cadaver model was used to compare the three experimental designs against the 1 mm control MSIs (total of 90 MSIs).

RESULTS

The synthetic bone model showed higher placement torque and pullout strength for the 0.75 pitch than for the 1.0 mm and 1.25 mm pitch MSIs, but differences were significant (P < .05) only for pullout strength. The cadaver model showed no significant differences in placement torque or pullout strength associated with pitch. Both synthetic and cadaver bone models showed that MSIs with flutes had significantly (P < .05) higher placement torque and pullout strength. Spearman correlations between placement torque and pullout strength were statistically significant for both synthetic (r = .504) and cadaver (r = .502) bone.

CONCLUSION

Within limits, decreasing MSI pitch increases pullout strength, and fluting increases both placement torque and pullout strength.

Does placing screws off-centre in tubular bone alter their pullout strength?

Screws are used to fix broken bones either directly or through plates. Surgeons sometimes find that a screw they have used is not quite in the centre of the bone but to one side or maybe even the edge. It has been postulated that screws catching the edge of the bone do not give good fixation and may even predispose to fractures. We conducted the present experiment using porcine femora to see if a screw's transverse plane position in the bone made any difference to its pullout strength. 20 cortical screws were inserted into the cortical segments of 5 pig femora (4 screws per femur) using the standard AO technique. The screws were inserted in one of 5 randomly chosen positions-centre, medial off-centre, lateral off-centre, medial edge and lateral edge. The screws were tested to failure in axial pullout using a Losenhausen universal testing machine. We found that 4 of the 8 'edge' screws failed with fractures developing around the screw track during pullout testing. These 4 screws were noted on cross-section to have 100% bone contact with their threads completely embedded in the cortical bone. They also had significantly lower pullout resistance than the 4 'edge' screws without fractures (p=0.05) and the 12 'non-edge' screws (in the central 75% of the bone) (p=0.03). This was most likely due to the associated fractures. There was a statistically significant association between the 'edge' screw position (i.e. within 12.5% of the medial or lateral edge of the bone) and the likelihood of fracture (p=0.000). We conclude that in the transverse plane, cortical screws either on their own or through plates should be inserted in the central three-fourths of the bone. Screws placed outside this zone carry a higher risk of fixation failure due to fractures around the screw track with axial loading.

The effect of the screw pull-out rate on cortical screw purchase in unreamed and reamed synthetic long bones

Orthopaedic fracture fixation constructs are typically mounted on to human long bones using cortical screws. Biomechanical studies are increasingly employing commercially available synthetic bones. The aim of this investigation was to examine the effect of the screw pull-out rate and canal reaming on the cortical bone screw purchase strength in synthetic bone. Cylinders made of synthetic material were used to simulate unreamed (foam-filled) and reamed (hollow) human long bone with an outer diameter of 35 mm and a cortex wall thickness of 4 mm. The unreamed and reamed cylinders each had 56 sites along their lengths into which orthopaedic cortical bone screws (major diameter, 3.5 mm) were inserted to engage both cortices. The 16 test groups ( n = 7 screw sites per group) had screws extracted at rates of 1 mm/min, 5 mm/min, 10 mm/min, 20 mm/min, 30 mm/min, 40 mm/min, 50 mm/min, and 60 mm/min. The failure force and failure stress increased and were highly linearly correlated with pull-out rate for reamed ( R2 = 0.60 and 0.60), but not for unreamed ( R2 = 0.00 and 0.00) specimens. The failure displacement and failure energy were relatively unchanged with pull-out rate, yielding low coefficients for unreamed ( R2 = 0.25 and 0.00) and reamed ( R2 = 0.27 and 0.00) groups. Unreamed versus reamed specimens were statistically different for failure force ( p = 0.000) and stress ( p = 0.000), but not for failure displacement ( p = 0.297) and energy (0.054< p<1.000). This is the first study to perform an extensive investigation of the screw pull-out rate in unreamed and reamed synthetic long bone.

Comparison and prediction of pullout strength of conical and cylindrical pedicle screws within synthetic bone

Background

This study was designed to derive the theoretical formulae to predict the pullout strength of pedicle screws with an inconstant outer and/or inner diameter distribution (conical screws). For the transpedicular fixation, one of the failure modes is the screw loosening from the vertebral bone. Hence, various kinds of pedicle screws have been evaluated to measure the pullout strength using synthetic and cadaveric bone as specimens. In the literature, the Chapman's formula has been widely proposed to predict the pullout strength of screws with constant outer and inner diameters (cylindrical screws).

Methods

This study formulated the pullout strength of the conical and cylindrical screws as the functions of material, screw, and surgery factors. The predicted pullout strength of each screw was compared to the experimentally measured data. Synthetic bones were used to standardize the material properties of the specimen and provide observation of the loosening mechanism of the bone/screw construct.

Results

The predicted data from the new formulae were better correlated with the mean pullout strength of both the cylindrical and conical screws within an average error of 5.0% and R² = 0.93. On the other hand, the average error and R² value of the literature formula were as high as -32.3% and -0.26, respectively.

Conclusion

The pullout strength of the pedicle screws was the functions of bone strength, screw design, and pilot hole. The close correlation between the measured and predicted pullout strength validated the value of the new formulae, so as avoid repeating experimental tests.

Pullout strength and load to failure properties of self-tapping cortical screws in synthetic and cadaveric environments representative of healthy and osteoporotic bone

BACKGROUND

The parameters of self-tapping screw (STS) performance in normal and osteoporotic bone have been defined in representative environments, but the question remains as to the clinical application of such findings. The goal of this study was to analyze the biomechanical performance of STSs in cadaveric and synthetic environments representative of healthy and osteoporotic bone.

METHODS

Ninety-six Synthes STSs were inserted into cadaveric and synthetic models representative of osteoporotic and healthy bone. Screws were inserted to depths of 1 mm short of the far cortex, flush and 1 mm and 2 mm beyond the far cortex. Screws were tested with an Instron 8511 material testing system utilizing axial pullout forces. A SAS procedure was used to conduct analysis of variance for unbalanced datasets.

RESULTS

Substantial differences were appreciated with respect to screw performance between osteoporotic and healthy bone specimens. Although a similar pattern of increased pullout strength and loading energy with increasing depth of insertion was demonstrated, absolute values were lower in osteoporotic specimens. Although performance trends were similar in cadaveric and synthetic testing models for both osteoporotic and healthy bone, values obtained during testing were different. Incomplete insertion of STSs resulted in a 21.5% and 37% reduction of biomechanical properties in osteoporotic and normal bone, respectively.

CONCLUSIONS

These results indicate that previously published findings on the performance of STSs in synthetic models cannot reasonably be applied to the clinical realm. Although trends may be similar, screw performance in synthetic, as compared with cadaveric, models is markedly different.

Insertion torque of orthodontic miniscrews according to changes in shape, diameter and length

OBJECTIVE

To determine the variation in the insertion torque of orthodontic miniscrews according to the screw length, diameter, and shape.

MATERIALS AND METHODS

The maximum insertion torque (MIT) was measured using a torque tester at a constant speed of 3 rotations per minute. Cylindrical and taper type of miniscrews (Biomaterials Korea Inc, Seoul, Korea) with different lengths, diameters, and pitches were tested.

RESULTS

The results showed that the insertion torque significantly increased with increasing screw length (P < .01). In particular, there was a significant increase in torque with increasing screw length and diameter (P < .01). An analysis of the serial insertion torque of miniscrews revealed the cylindrical type screw to have much higher insertion torque at the incomplete screw thread, while the taper type screw showed a much higher insertion torque at the final inclination part of the screw thread. The insertion torque was affected by the outer diameter, length, and shape in that order.

CONCLUSIONS

An increase in screw diameter can efficiently reinforce the initial stability of the miniscrew, but the proximity of the root at the implanted site should be considered.

Cortical screw pullout strength and effective shear stress in synthetic third generation composite femurs

BACKGROUND

The use of artificial bone analogs in biomechanical testing of orthopaedic fracture fixation devices has increased, particularly due to the recent development of commercially available femurs such as the third generation composite femur that closely reproduce the bulk mechanical behavior of human cadaveric and/or fresh whole bone. The purpose of this investigation was to measure bone screw pullout forces in composite femurs and determine whether results are comparable to cadaver data from previous literature.

METHOD OF APPROACH

The pullout strengths of 3.5 and 4.5 mm standard bicortical screws inserted into synthetic third generation composite femurs were measured and compared to existing adult human cadaveric and animal data from the literature.

RESULTS

For 3.5 mm screws, the measured extraction shear stress in synthetic femurs (23.70-33.99 MPa) was in the range of adult human femurs and tibias (24.4-38.8 MPa). For 4.5 mm screws, the measured values in synthetic femurs (26.04-34.76 MPa) were also similar to adult human specimens (15.9-38.9 MPa). Synthetic femur results for extraction stress showed no statistically significant site-to-site effect for 3.5 and 4.5 mm screws, with one exception. Overall, the 4.5 mm screws showed statistically higher stress required for extraction than 3.5 mm screws.

CONCLUSIONS

The third generation composite femurs provide a satisfactory biomechanical analog to human long-bones at the screw-bone interface. However, it is not known whether these femurs perform similarly to human bone during physiological screw "toggling."

A surrogate long-bone model with osteoporotic material properties for biomechanical testing of fracture implants

In vitro comparative testing of fracture fixation implants is limited by the highly variable material properties of cadaveric bone. Bone surrogate specimens are often employed to avoid this confounding variable. Although validated surrogate models of normal bone (NB) exist, no validated bone model simulating weak, osteoporotic bone (OPB) is available. This study presents an osteoporotic long-bone model designed to match the lower cumulative range of mechanical properties found in large series of cadaveric femora reported in the literature. Five key structural properties were identified from the literature: torsional rigidity and strength, bending rigidity and strength, and screw pull-out strength. An OPB surrogate was designed to meet the low range for each of these parameters, and was mechanically tested. For comparison, the same parameters were determined for surrogates of NB. The OPB surrogate had a torsional rigidity and torsional strength within the lower 2% and 16%, respectively, of the literature based cumulative range reported for cadaveric femurs. Its bending rigidity and bending strength was within the lower 11% and 8% of the literature-based range, respectively. Its pull-out strength was within the lower 2% to 16% of the literature based range. With all five structural properties being within the lower 16% of the cumulative range reported for native femurs, the OPB surrogate reflected the diminished structural properties seen in osteoporotic femora. In comparison, surrogates of NB demonstrated structural properties within 23-118% of the literature-based range. These results support the need and utility of the OPB surrogate for comparative testing of implants for fixation of femoral shaft fractures in OPB.

Effect of screw torque level on cortical bone pullout strength

OBJECTIVES

The objectives of this study were 2-fold: (1) to perform detailed analysis of cortical screw tightening stiffness during automated insertion, and (2) to determine the effect of 3 torque levels on the holding strength of the bone surrounding the screw threads as assessed by screw pullout.

METHODS

Ten pairs of ovine tibiae were used with 3 test sites spaced 20 mm apart centered along the shaft. One side of each pair was used for measuring ultimate failure torque (Tmax). These Tmax and bone-density values were used to predict Tmax at contralateral tibia sites. Screws were inserted and tightened to 50%, 70%, and 90% of predicted Tmax at the contralateral sites to encompass the average clinical level of torque (86% Tmax). Pullout tests were performed and maximum force values were normalized by cortical thickness.

RESULTS

Torque to failure tests indicated tightening to 86% Tmax occurs after yield and leads to an average 51% loss in stiffness. Normalized pullout strength for screws tightened to 50% Tmax, 70% Tmax, and 90% Tmax were 2525 +/- 244, 2707 +/- 280, and 2344 +/- 346 N, respectively, with a significant difference between 70% Tmax and 90% Tmax groups (P < 0.05).

CONCLUSIONS

Within the limitations of our study involving the testing of 1 type of screw purchase in ovine tibiae, results demonstrate that clinical levels of lag screw tightening (86% Tmax) are past the yield point of bone. Tightening to these high torque levels can cause damage leading to compromised holding strength. Further research is still required to establish the appropriate level of torque required for achieving optimal fracture fixation and healing.

Experimental evaluation of the holding power/stiffness of the self-tapping bone screws in normal and osteoporotic bone material

OBJECTIVE

The goal of this study is to compare the holding power of the self-tapping bone screws in normal and osteoporotic bone materials.

BACKGROUND

Self-tapping screws are increasingly being used in orthopaedic surgery due to their advantages over the other bone screws.

METHODS

Screws were divided into five groups (six screws per group) based on the depth of insertion in the bone coupons that represented normal and osteoporotic bones. Screws were randomly inserted into the bone coupons with tips of the screws being -1 mm, 0 mm, 1 mm, 2 mm and 3 mm relative to the far cortex. Biomechanical testing was performed using an Instron 8,511 in accordance with the American Society for Testing and Materials standards for bone screws. Two-factor analysis of variance (ANOVA) was used to determine if the holding power of the screws were different with respect to insertion depths and bone materials.

FINDINGS

The bone materials had a significant difference (P < 0.05) in the holding power and depths of insertion past the far cortex were significantly different from one another in holding power. The affect of the screw material on the holding power of the self-tapping screws in different bone materials was also examined. The performance of stainless steel screws was superior to that of titanium screws in the osteoporotic material.

INTERPRETATION

Based on the results it can be concluded that the depth of insertion of the tip of the screw for adequate fracture fixation in normal bone is 1mm or more past the far cortex and in osteoporotic bone it is at least 2mm past the far cortex.

Biomechanical Evaluation of the Pullout Strength of Cervical Screws

OBJECTIVE

In the process of anterior cervical fusion, little is known about the biomechanics of anterior cervical screw pullout. In this study, three different aspects of cervical screw fixation were evaluated: self-tapping (ST) versus self-drilling (SD) screws, the effect of screw geometry (length, diameter, thread pitch), and the use of rescue screws.

METHODS

Nine screws consisting of different diameters, lengths, and thread pitch (cancellous and cortical) were tested in peak pullout force in an artificial bone model using an MTS 858 Mini Bionix test system. Rescue screws (4.5 mm) were then inserted in the failed holes of 4.0-mm screws and extracted to determine their holding strength.

RESULTS

Length of screws and thread pitch both had a significant effect on the pullout force. Each 1 mm of increased screw length translates to 16 N of increased force to pullout in the foam bone model. Pullout strength did not vary significantly according to screw diameter or between SD and ST screws. However, the SD screw has an advantage because it can decrease the length of surgery. A decrease in pullout force of between 43% and 70% was found when using rescue screws.

CONCLUSIONS

In situations in which the use of rescue/salvage screws is required, the surgeon should anticipate a significant decrease in the holding force compared with the original screw. Future directions for research include an evaluation of pullout force for screw and plate constructs.

Pullout strength of self-tapping screws inserted to different depths

OBJECTIVES

The purpose of this study was to determine whether the depth of insertion through the far cortex of self-tapping screws significantly affects pullout strength.

DESIGN

Fifty, Synthes, 3.5-mm, self-tapping screws were inserted into synthetic bone blocks and divided into 5 groups. Group 1 had screws with their tips inserted 1 mm short of the far cortex. Group 2 had screws inserted flush with the far cortex. Groups 3, 4, and 5 had screws inserted 1 mm, 2 mm, and 3 mm past the far cortex respectively. Pullout strength was then tested.

SETTING

Institutional research laboratory.

MAIN OUTCOME MEASUREMENTS

Pullout strength (peak force) was measured for each group and analyzed using a single factor analysis of variance-balanced incomplete block design.

RESULTS

Peak force values presented as mean +/- SD for the 5 groups were as follows: group 1 (1380 +/- 69 N), group 2 (1566 +/- 137 N), group 3 (1956 +/- 137 N), group 4 (2013 +/- 184 N), group 5 (2044 +/- 174 N). With a P < or = 0.05, it was found that groups I and II had statistically different pullout strengths than all other groups. However, there was no significant difference in pullout strength between groups 3, 4, and 5.

CONCLUSIONS

Synthes self-tapping screws exhibit their highest pullout strength when inserted 1 mm past the far cortex, and there is no significant increase in pullout strength with deeper insertion depths.

Effect of bone mineral density and amorphous diamond coatings on insertion torque of bone screws

In this study, the potential of high-quality amorphous diamond (AD) coatings in reducing the torque and failures of bone screws was studied. Torque values were recorded for 32 stainless steel screws, 2.7 or 3.5 mm in diameter and 60 mm in length. Half of the screw sets were coated with the AD coating before installing in predrilled holes of human cadaveric femoral bone samples. The bone samples were selected from two groups of four persons with mean ages of 34 years (range 25-41 years) and 75 years (range 73-77 years), respectively. The bone mineral density (BMD) values of the samples were determined exactly at the screw insertion site by peripheral quantitative computed tomography (pQCT). In the mechanical tests, insertion and removal torques were measured. BMD had a significant effect on insertion torque; the maximum torque (adjusted with respect to the screw diameter) was significantly higher for the young bone than for the old bone (p < 0.05). By using a polished AD coating, insertion torque was decreased even up to 50% in comparison with the screws without coating. The results suggest that AD coating provides a stable, smooth surface and reduces the risk of screw failures.

Oblique screws at the plate ends increase the fixation strength in synthetic bone test medium

OBJECTIVE

To test the hypothesis that oblique screws at the ends of a plate provide increased strength of fixation as compared to standard screw insertion.

DESIGN

Biomechanical laboratory study in synthetic bone test medium.

METHODS

Narrow 4.5-mm stainless steel low-contoured dynamic compression plates were anchored with cortical screws to blocks of polyurethane foam. The fixation strength in cantilever bending (gap closing mode) and torsion was quantified using a material testing system. Different constructs were tested to investigate the effect of the screw orientation at the end of the plate (straight versus oblique at 30 degrees), the plate, and bridging length as well as the number of screws.

RESULTS

An oblique screw at the plate end produced an increased strength of fixation in all tests; however, the difference was more significant in shorter plates and in constructs with no screw omission adjacent to the fracture site. Both longer plates and increased bridging length produced a significantly stronger construct able to withstand higher compression loads. Under torsional loading, the fixation strength was mainly dependent on the number of screws.

CONCLUSIONS

The current data suggest that when using a conventional plating technique, plate length is the most important factor in withstanding forces in cantilever bending. With regard to resisting torsional load, the number of screws is the most important factor. Furthermore, oblique screws at the ends of a plate increase fixation strength.

Mechanical characteristics of the new BONE-LOK bi-cortical internal fixation device

The purpose of this study was to evaluate the mechanical characteristics of a new and unique titanium compression anchor with BONE-LOK (Triage Medical, Inc, Irvine, CA) technology for compressive, bi-cortical internal fixation of bone. This device provides fixation through the use of a distal grasping anchor and an adjustable proximal collar that are joined by an axially movable pin and guide wire. The titanium compression anchor, in 2.0-, 2.7-, and 3.5-mm diameters, were compared with cortex screws (Synthes USA, Paoli, PA) of the same diameter and material for pullout strength in 20 lb/cu ft and 30 lb/cu ft solid rigid polyurethane foam; and for compression strength in 20 lb/cu ft foam. Retention strength of the collar was tested independently. The results showed significantly greater pullout strength of the 2.7-mm and 3.5-mm titanium compression anchor as compared with the 2.7-mm and 3.5-mm cortex screws in these test models. Pullout strength of the 2.0-mm titanium compression anchor was not statistically different in comparison with the 2.0-mm cortical screws. Compression strength of the titanium compression anchor was significantly greater than the cortical screws for all diameters tested. These differences represent a distinct advantage with the new device, which warrants further in vivo testing. Collar retention strength testing values were obtained for reference only and have no comparative significance.