Surgeon perception of cancellous screw fixation

Biomechanical comparison of two different compression screws for the treatment of odontoid fractures in human dens axis specimen

BACKGROUND

Lag screw osteosynthesis for odontoid fractures has a high rate of pseudoarthrosis, especially in elderly patients. Besides biomechanical properties of the different screw types, insufficient fragment compression or unnoticed screw stripping may be the main causing factors for this adverse event. The aim of the study was to compare two screws in clinical use with different design principles in terms of compression force and stability against screw stripping.

METHODS

Twelve human cadaveric C2 vertebral bodies were considered. Bone density was determined. The specimens were matched according to bone density and randomly assigned to two experimental groups. An odontoid fracture was induced, which were fixed either with a 3.5 mm standard compression screw or with a 5 mm sleeve nut screw. Both screws are certified for the treatment of odontoid fractures. The bone samples were fixed in a measuring device. The screwdriver was driven mechanically. The tests were analyzed for peak interfragmentary compression and screw-in torque with a frequency of 20 Hz.

FINDINGS

The maximum fragment compression was significantly higher with screw with sleeve nut at 346.13(SD ±72.35) N compared with classic compression screw at 162.68(SD ±114.13) N (p = 0.025). Screw stripping occurred significantly earlier in classic compression screw at 255.5(SD ±192.0)° rotation after reaching maximum compression than in screw with sleeve nut at 1005.2(SD ±341.1)° (p = 0.0039).

INTERPRETATION

Screw with sleeve nut achieves greater fragment compression and is more robust to screw stripping compared to classic compression screw. Whether the better biomechanical properties lead to a reduction of pseudoarthrosis has to be proven in clinical studies.

Biomechanical Variability and Usability of a Novel Customizable Fracture Fixation Technique

A novel in situ customizable osteosynthesis technique, Bonevolent™ AdhFix, demonstrates promising biomechanical properties under the expertise of a single trained operator. This study assesses inter- and intra-surgeon biomechanical variability and usability of the AdhFix osteosynthesis platform. Six surgeons conducted ten osteosyntheses on a synthetic bone fracture model after reviewing an instruction manual and completing one supervised osteosynthesis. Samples underwent 4-point bending tests at a quasi-static loading rate, and the maximum bending moment (BM), bending stiffness (BS), and AdhFix cross-sectional area (CSA: mm²) were evaluated. All constructs exhibited a consistent appearance and were suitable for biomechanical testing. The mean BM was 2.64 ± 0.57 Nm, and the mean BS was 4.35 ± 0.44 Nm/mm. Statistically significant differences were observed among the six surgeons in BM (p < 0.001) and BS (p = 0.004). Throughout ten trials, only one surgeon demonstrated a significant improvement in BM (p < 0.025), and another showed a significant improvement in BS (p < 0.01). A larger CSA corresponded to a statistically significantly higher value for BM (p < 0.001) but not for BS (p = 0.594). In conclusion, this study found consistent biomechanical stability both across and within the surgeons included, suggesting that the AdhFix osteosynthesis platform can be learned and applied with minimal training and, therefore, might be a clinically viable fracture fixation technique. The variability in BM and BS observed is not expected to have a clinical impact, but future clinical studies are warranted.

Segmenting/Pre-Processing Data from Bone Screw Thread-Stripping Tests

Bone screws must be appropriately tightened to achieve optimal patient outcomes. If over-torqued, the threads formed in the bone may break, compromising the strength of the fixation; and, if under-torqued, the screw may loosen over time, compromising the stability. Previous work has proposed a model-based system to automatically determine the optimal insertion torque. This system consists of a reverse-modelling step to determine strength, and a forward modelling step to determine maximum torque. These have previously been tested in isolation, however future work must test the combined system. To do so, the data must be segmented and pre-processed. This was done based on specific features of the recorded data. The methodology was tested on 50 screw-insertion data sets across 5 different materials. With the parameters used, all data sets were correctly segmented. This will form a basis for the further processing of the data and validating the combined systemClinical relevance: The system for torque limit determination must be tested in its entirety to properly asses its performance. This paper discusses some of the steps required to pre-process the data to make this assessment. If successful, this system may improve patient outcomes in orthopaedic surgery.

Anatomical and Biomechanical Stability of Single/Double Screw-Cancellous Bone Fixations of Regan-Morry Type III Ulnar Coronoid Fractures in Adults: CT Measurement and Finite Element Analysis

OBJECTIVE

At present, it is still uncertain whether single screw has the same stability as double screws in the treatment of ulnar coronal process basal fracture (Regan-Morry type III). So, we aimed to compare the pull-out force and anti-rotation torque of anterior single/double screw-cancellous bone fixation (aSSBF, aDSBF) in this fracture, and further study the influencing factors on anatomical and biomechanical stability of smart screw internal fixations.

METHODS

A total of 63 adult volunteers with no history of elbow injury underwent elbow CT scanning with associated three-dimensional reconstruction that enabled the measurements of bone density and fixed length of the proximal ulna and coronoid. The models of coronal process basal fracture, aSSBF and aDSBF, were developed and validated. Using the finite element model test, the sensitivity analysis of pull-out force and rotational torque was carried out.

RESULTS

The pull-out force of aSSBF model was positively correlated with the density of the cancellous bone and linearly related to the fixed depth of the screw. The load pattern of pull-out force of aDSBF model was similar to that of aSSBF model. The ultimate torque of aDSBF model was higher than that of aSSBF model, but the load pattern of ultimate torque of both models was similar to each other when the fracture reset was satisfactory, and the screw nut attaches closely to coronoid process. Moreover, with enhancement of initial pre-tightening force, the increase of ultimate torque of both models was small.

CONCLUSIONS

In addition to three pull-out stability factors of smart screw fixations, fracture surface fitting degree and nut fitting degree are the other two important anatomical and biomechanical stability factors of smart screw fixations both for rotational stability. When all pull-out stability and rotational stability factors meet reasonable conditions simultaneously, single or double screw fixation methods are stable for the treatments of ulnar coronoid basal fractures.

Augmented screwdrivers can increase the performance of orthopaedic surgeons compared with use of normal screwdrivers

Orthopaedic screws insertion can be trivialised as a simple procedure, however it is frequently performed poorly. Limited work exists defining how well surgeons insert screws or whether augmented screwdrivers can aid surgeons to reduce stripping rates and optimise tightness. We aimed to establish the performance of surgeons inserting screws and whether this be improved with screwdriver augmentation. 302 orthopaedic surgeons tightened 10 non-locking screws to what they determined to be optimum tightness into artificial bone sheets. The confidence in the screw purchase was given (1-10). A further 10 screws were tightened, using an augmented screwdriver that indicated when a predetermined optimum tightness was reached. The tightness for unstripped insertions under normal conditions and with the augmented screwdriver were 81% (95% CI 79-82%)(n = 1275) and 70% (95% CI 69-72%)(n = 2577) (p < 0.001). The stripping rates were 58% (95% CI 54-61%) and 15% (95% CI 12-17%) respectively (p < 0.001). The confidences when using the normal and augmented screwdrivers respectively were 7.2 and 7.1 in unstripped insertions and 6.2 and 6.5 in stripped insertions. Performance improved with an augmented screwdriver, both in reduced stripping rates and greater accuracy in detecting stripping. Augmenting screwdrivers to indicate optimum tightness offer potentially enormous clinical benefits by improving screw fixation.

Orthopedic screws insertion simulation with immediate feedback enhances surgical skill

BACKGROUND

Screw insertion to bones is a fundamental skill in orthopedic, spine and cranio-maxillofacial surgery. Applying the correct tightening torque is critical when compressing and fixating bone fragments. Overtightening yields in plastic deformation of the bone and destruction of the screw-bone interface, damaging the construct's stability. The surgeon is required to achieve sufficient hold and compression without stripping the bone. Several studies have investigated these skills, demonstrating much potential to enhance the future surgeons' capabilities. This study presents a novel training module, combining direct tightening followed by deliberate striping with immediate feedback suggested to enhance the surgeon's tactile perception and improve skill.

METHODS

A prospective single-blinded cohort study was run. Twenty surgeons from various disciplines, excluding orthopedic and maxillo-facial surgeons, were trained using an orthopedic screws insertion model, comprised of synthetic bones. Training sessions considered inserting 40 screws into normal and osteoporotic bone models, experiencing deliberate stripping of the screws and feedback for their performance in three different sessions.

FINDINGS

Success rate increased between sessions - by 24% to 48% in normal bone, and by 37% to 52% in osteoporotic bone. Stripping rate decreased between sessions - by 37.5% to 18.5% in normal bone, and by 29% to 14% in osteoporotic bone. Average ratio between tightening torque and maximum possible torque before bone stripping improved gradually and consistently from 67.3% to 81.6% in normal bone (p < 0.001), and slightly from 76.4% to 77.5% in osteoporotic bone (p = 0.026).

INTERPRETATION

Immediate feedback with deliberate stripping and external feedback using a digital torque measuring screwdriver may improve cortical screw insertion technique in the surgeons' community.

Geometric Generalization of Self Tapping Screw Insertion Model

Bone screws are used in orthopaedic procedures to fix implants and stabilise fractures. These procedures require care, as improperly torquing the screws can lead to implant failure or tissue damage, potentially requiring revision surgery or causing further disability. It was proposed that automated torque-limit identification may allow clinical decision support to control the screw torque, and lead to improved patient outcomes. This work extends a previous model of the screw insertion process to model complex thread geometries used for bone screws; consideration was made for the variable material properties and behaviours of bone to allow further tuning in the future. The new model was simulated and compared with the original model. The model was found to be in rough agreement with the earlier model, but was distinct, and could model thread features that the earlier model could not, such as the fillets and curves on the bone screw profile. The new model shows promise in modelling the more advanced thread geometries of bone screws with higher accuracy.Clinical relevance: This work extends a self tapping screw model to support complex thread shapes, as common in bone screws, allowing more accurate modelling of the clinically relevant geometries.

Investigating Torque-Speed Relationship of Self-Tapping Screws

Correctly torquing bone screws is important to prevent fixation failures and ensure positive patient outcomes. It has been proposed that an automatic model-based method may be able to determine the patient-specific material properties of bone, and provide objective and quantitative torquing recommendations. One major part of developing this system is the modelling of the bone-screwing process, and the self-tapping screwing process in general. In this paper, we investigate the relationship between screw insertion torque (Nm) and speed of insertion (RPM). A weak positive correlation was found below approximately 30 RPM. Further research should focus on increasing the precision of the methodology, and this testing must be extended to ex-vivo animal bone testing in addition to the polyurethane foam substitute used here.Clinical relevance: To maximise the accuracy of torque recommendations, the model should account for all important factors. This study investigates and attempts to quantify the relationship between screw insertion speed and torque for later inclusion in modelling if significant.

Quantifying Accuracy of Self-Tapping Screw Models

Correct torquing of bone screws is important to prevent fixation failures and ensure positive patient outcomes. It has been proposed that an automatic model-based method may be able to determine the patient-specific material properties of bone, and provide objective and quantitative torquing recommendations. Models have been previously proposed for identifying the bone material properties, but have not been experimentally tested for accuracy. Here we used these models to perform parameter identification on experimental data using a variety of materials (rigid polyurethane foams) and screws. The identified values were then compared to the values from the datasheet, and matched with a reasonable accuracy for medium-density foam. It was found that for the lower-density foam, the model slightly under-predicted the strength, and for the highest density foam there was a large under-prediction. This suggests that with appropriate calibration, this method is good, but may only be applicable to lower-to-medium strength materials. More thorough testing is required to confirm this and determine the reliable density range.Clinical relevance: Accurate material property identification is required to provide effective torque recommendations for bone screws. This work quantifies the accuracy of two proposed models for material property identification.

Screw tightness and stripping rates vary between biomechanical researchers and practicing orthopaedic surgeons

BACKGROUND

Screws are the most frequently inserted orthopaedic implants. Biomechanical, laboratory-based studies are used to provide a controlled environment to investigate revolutionary and evolutionary improvements in orthopaedic techniques. Predominantly, biomechanical trained, non-surgically practicing researchers perform these studies, whilst it will be orthopaedic surgeons who will put these procedures into practice on patients. Limited data exist on the comparative performance of surgically and non-surgically trained biomechanical researchers when inserting screws. Furthermore, any variation in performance by surgeons and/or biomechanical researchers may create an underappreciated confounder to biomechanical research findings. This study aimed to identify the differences between surgically and non-surgically trained biomechanical researchers' achieved screw tightness and stripping rates with different fixation methods.

METHODS

Ten orthopaedic surgeons and 10 researchers inserted 60 cortical screws each into artificial bone, for three different screw diameters (2.7, 3.5 and 4.5 mm), with 50% of screws inserted through plates and 50% through washers. Screw tightness, screw hole stripping rates and confidence in screw purchase were recorded. Three members of each group also inserted 30 screws using an augmented screwdriver, which indicated when optimum tightness was achieved.

RESULTS

Unstripped screw tightness for orthopaedic surgeons and researchers was 82% (n = 928, 95% CI 81-83) and 76% (n = 1470, 95% CI 75-76) respectively (p < 0.001); surgeons stripped 48% (872/1800) of inserted screws and researchers 18% (330/1800). Using washers was associated with increased tightness [80% (95% CI 80-81), n = 1196] compared to screws inserted through plates [76% (95% CI 75-77), n = 1204] (p < 0.001). Researchers were more accurate in their overall assessment of good screw insertion (86% vs. 62%). No learning effect occurred when comparing screw tightness for the first 10 insertions against the last 10 insertions for any condition (p = 0.058-0.821). Augmented screwdrivers, indicating optimum tightness, reduced stripping rates from 34 to 21% (p < 0.001). Experience was not associated with improved performance in screw tightness or stripping rates for either group (p = 0.385-0.965).

CONCLUSIONS

Surgeons and researchers showed different screw tightness under the same in vitro conditions, with greater rates of screw hole stripping by surgeons. This may have important implications for the reproducibility and transferability of research findings from different settings depending on who undertakes the experiments.

Revising a loosened cancellous screw with a larger screw does not restore original pull-out strength - A biomechanical study

BACKGROUND

Cancellous screw fixation is often used in fracture fixation. When this screw is over-tightened, damage to the bone and other non-linear processes such as fracture and construct failure would be involved. The objectives of this study were (1) to determine the reduction in pull-out strength when a cancellous screw spins and (2) to determine how much pull-out strength can be restored by revising with a larger diameter screw.

METHODS

A biomechanical study using synthetic polyurethane foam (320 kg/m³) was performed to assess (1) the pull-out strength of a 6.5 mm cancellous screw, (2) the pull-out strength of a loosened 6.5 mm cancellous screw and (3) the pull-out strength of a loosened 6.5 mm cancellous screw revised with a 7.3 mm cancellous screw.

FINDINGS

The baseline pull-out strength of the 6.5 mm cancellous screw was 2213.91 ± 200.51 N. There was a 79.1% (463.79 ± 99.95 N) reduction in pull-out strength once spinning occurs (p = 0.027). When a spinning 6.5 mm cancellous screw was revised to a 7.3 mm cancellous screw, the pull-out strength increased to 1313.65 ± 93.23 N, 59.3% of the baseline pull-out strength (2213.91 ± 200.51 N) (p = 0.027).

INTEPRETATION

A loosened 6.5 mm cancellous screw results in a 79.1% reduction in pull-out strength. Revising a loosened cancellous screw by inserting a larger 7.3 mm diameter screw partially improves the pull-out strength to 59.3% of the baseline. Surgeons should consider the use of "two-finger tight" torque when inserting a screw to avoid stripping.

Salvaging Pull-Out Strength in a Previously Stripped Screw Site: A Comparison of Three Rescue Techniques

Screw stripping during bone fixation is a common occurrence during operations that results in decreased holding capacity and bone healing. We aimed to evaluate the rescue of the stripped screw site using screws of different dimensions. Five screw configurations were tested on cadaveric specimens for pull-out strength (POS). The configurations included a control screw tightened without stripping, a configuration voluntarily stripped and left in place, and three more configurations in which the stripped screws were replaced by a different screw with either increased overall length, diameter, or thread length. Each configuration was tested five times, with each screw tested once. The POS of the control screw, measured to be 153.6 ± 27 N, was higher than the POS measured after stripping and leaving the screw in place (57.1 ± 18 N, p = 0.001). The replacement of the stripped screw resulted in a POS of 158.4 ± 64 N for the screw of larger diameter, while the screws of the same diameter but increased length or those with extended thread length yielded POS values of 138.4 ± 42 and 185.7 ± 48 N, respectively. Screw stripping is a frequent intraoperative complication that, according to our findings, cannot be addressed by leaving the screw in place. The holding capacity of a stripped screw implanted in cancellous bone can successfully be restored with a different screw of either larger diameter, longer length, or extended thread length.

Temporal Changes in Reverse Torque of Locking-Head Screws Used in the Locking Plate in Segmental Tibial Defect in Goat Model

The objective of this study was to evaluate changes in peak reverse torque (PRT) of the locking head screws that occur over time. A locking plate construct, consisting of an 8-hole locking plate and 8 locking screws, was used to stabilize a tibia segmental bone defect in a goat model. PRT was measured after periods of 3, 6, 9, and 12 months of ambulation. PRT for each screw was determined during plate removal. Statistical analysis revealed that after 6 months of loading, locking screws placed in position no. 4 had significantly less PRT as compared with screws placed in position no. 5 (p < 0.05). There were no statistically significant differences in PRT between groups as a factor of time (p > 0.05). Intracortical fractures occurred during the placement of 151 out of 664 screws (22.7%) and were significantly more common in the screw positions closest to the osteotomy (positions 4 and 5, p < 0.05). Periosteal and endosteal bone reactions and locking screw backout occurred significantly more often in the proximal bone segments (p < 0.05). Screw backout significantly, negatively influenced the PRT of the screws placed in positions no. 3, 4, and 5 (p < 0.05). The locking plate-screw constructs provided stable fixation of 2.5-cm segmental tibia defects in a goat animal model for up to 12 months.

Variations in non-locking screw insertion conditions generate unpredictable changes to achieved fixation tightness and stripping rates

BACKGROUND

Screws are the most commonly inserted orthopaedic implants. However, several variables related to screw insertion and tightening have not been evaluated. This study aimed firstly to assess the effect of insertion variables on screw tightness, secondly to improve methodologies used by researchers when testing screw insertion techniques and thirdly to assess for any learning or fatigue effects when inserting screws.

METHODS

Two surgeons tightened a total of 2280 non-locking, 3.5 mm cortical screws, with 120 screws inserted to what they felt to be optimum tightness whilst varying each of the following factors: different screwdrivers for measuring torque, screwdriver orientation, gloves usage, dominant/non-dominant hand usage, awareness to the applied torque (blinded, unblinded and re-blinded), four bone densities and seven cortical thicknesses. Screws were tightened to failure to determine stripping torque, which was used to calculate screw tightness - ratio between stopping and stripping torque.

FINDINGS

Screw tightness increased with glove usage, being blinded to the applied torque and with denser artificial bone and with thinner cortices. Considering all the insertions performed, the two surgeons stopped tightening screws at difference values of tightness ((77% versus 66% (p < 0.001)). A learning effect was observed with some parameters including sterile gloves usage and non-dominant hand application.

INTERPRETATION

Different insertion conditions frequently changed screw tightness for both surgeons. Given the influence of screw tightness on fixation stability, the variables investigated within this study should be carefully reported and controlled when performing biomechanical testing alongside practicing screw insertion under different conditions during surgical training.

Biomechanical comparison of three different compression screws for treatment of odontoid fractures evaluation of a new screw design

BACKGROUND

Lag screw osteosynthesis in odontoid fractures shows a high rate of pseudarthrosis. Biomechanical properties may play a role with insufficient fragment compression or unnoticed screw stripping. A biomechanical comparison of different constructed lag-screws was carried out and the biomechanical properties determined.

METHODS

Two identical compression screws with different pilot holes (1.25 and 2.5 mm), a double-threaded screw and one sleeve-nut-screw were tested on artificial bone (Sawbone, densities 10-30pcf). Fragment compression and torque were continuously measured using thin-film force sensors (Flexiforce A201, Tekscan) and torque sensors (PCE-TM 80, PCE GmbH).

FINDINGS

The lowest compression reached the double-threaded screw. Compression and sleeve-nut-screw achieved 214-298% and 325-546%, respectively, of the compression force of double-threaded-screw, depending on the test material. The pilot hole optimization led to a significant improvement in compression only in the densest test material. Screw stripping took place significantly later with increasing density of the test material on all screws. In compression screws this was done at a screw rotation of 180-270°, in sleeve nut screw at 270-720° and in double-threaded screws at 300-600° after reaching the maximum compression.

INTERPRETATION

Double-threaded screw is robust against screw stripping, but achieves only low fragment compression. The classic compression screws achieve better compression, but are sensitive to screw stripping. Sleeve-nut screw is superior in compression and as robust as double-threaded screw against screw stripping. Whether the better biomechanical properties lead to a reduction in pseudarthrosis must be proven in clinical trials.

Real time monitoring of screw insertion using acoustic emission can predict screw stripping in human cancellous bone

BACKGROUND

To develop experience, orthopaedic surgeons train their own proprioception to detect torque during screw insertion. This experience is acquired over time and when implanting conventional/non-locked screws in osteopenic cancellous bone the experienced surgeon still strips between 38 and 45%. Technology needs to be investigated to reduce stripping rates. Acoustic-Emission technology has the ability to detect stress wave energy transmitted through a screw during insertion into synthetic bone. Our hypothesis is Acoustic-Emission waves can be detected through standard orthopaedic screwdrivers while advancing screws through purchase and overtightening in cancellous human bone with different bone mineral densities replicating the clinical state.

METHODS

77 non-locking 4 mm and 6.5 mm diameter cancellous bone screws were inserted through to stripping into the lateral condylar area of 6 pairs of embalmed distal femurs. Specimens had varying degrees of bone mineral density determined by quantitative CT. Acoustic-Emission energy and axial force were detected for each test.

RESULTS

The tests showed a significant high correlation between bone mineral density and Acoustic-Emission energy with R = 0.74. A linear regression model with the mean stripping load as the dependent variable and mean Acoustic-Emission energy, bone mineral densities and screw size as the independent variables resulted in r² = 0.94.

INTERPRETATION

This experiment succeeded in testing real time Acoustic-Emission monitoring of screw purchase and overtightening in human bone. Acoustic-Emission energy and axial compressive force have positive high correlation to bone mineral density. The purpose is to develop a known technology and apply it to improve the bone-metal construct strength by reducing human error of screw overtightening.

Surgical performance when inserting non-locking screws: a systematic review

Billions of screws are inserted by surgeons each year, making them the most commonly inserted implant. When using non-locking screws, insertion technique is decided by the surgeon, including how much to tighten each screw. The aims of this study were to assess, through a systematic review, the screw tightness and rate of material stripping produced by surgeons and the effect of different variables related to screw insertion.

Twelve studies were included, with 260 surgeons inserting a total of 2793 screws; an average of 11 screws each, although only 1510 screws have been inserted by 145 surgeons where tightness was measured – average tightness was 78±10% for cortical (n = 1079) and 80±6% for cancellous screw insertions (n = 431).

An average of 26% of all inserted screws irreparably damaged and stripped screw holes, reducing the construct pullout strength. Furthermore, awareness of bone stripping is very poor, meaning that screws must be considerably overtightened before a surgeon will typically detect it.

Variation between individual surgeons’ ability to optimally insert screws was seen, with some surgeons stripping more than 90% of samples and others hardly any. Contradictory findings were seen for the relationship between the tightness achieved and bone density.

The optimum tightness for screws remains unknown, thus subjectively chosen screw tightness, which varies greatly, remains without an established target to generate the best possible construct for any given situation. Work is needed to establish these targets, and to develop methods to accurately and repeatably achieve them.

Cite this article: EFORT Open Rev 2020;5:26-36. DOI: 10.1302/2058-5241.5.180066

Non-locking screw insertion: No benefit seen if tightness exceeds 80% of the maximum torque

BACKGROUND

Millions of non-locking screws are manually tightened during surgery each year, but their insertion frequently results in overtightening and damage to the surrounding bone. We postulated that by calculating the torque limit of a screw hole, using bone and screw properties, the risk of overtightening during screw insertion could be reduced. Additionally, predicted maximum torque could be used to identify optimum screw torque, as a percentage of the maximum, based on applied compression and residual pullout strength.

METHODS

Longitudinal cross-sections were taken from juvenile bovine tibial diaphyses, a validated surrogate of human bone, and 3.5 mm cortical non-locking screws were inserted. Fifty-four samples were used to define the association between stripping torque and cortical thickness. The relationship derived enabled prediction of insertion torques representing 40 to 100% of the theoretical stripping torque (T_str) for a further 170 samples. Screw-bone compression generated during insertion was measured, followed immediately by axial pullout testing.

FINDINGS

Screw-bone compression increased linearly with applied torque up to 80% of T_str (R² = 0.752, p < 0.001), but beyond this, no significant further compression was generated. After screw insertion, with all screw threads engaged, more tightening did not create any significant (R² = 0.000, p = 0.498) increase in pullout strength.

INTERPRETATION

Increasing screw tightness beyond 80% of the maximum did not increase screw-bone compression. Variations in torques below T_str, did not affect pullout forces of inserted screws. Further validation of these findings in human bone and creation of clinical guidelines based on this research approach should improve surgical outcomes and reduce operative costs.

Teaching Cortical-Screw Tightening: A Simple, Affordable, Torque-Directed Training Protocol Improves Resident Performance

BACKGROUND

Cortical-screw insertion is a fundamental skill in orthopaedic surgery, yet, to our knowledge, no standardized method of teaching this skill exists. The purpose of this study was to evaluate a training protocol that was designed to teach residents how to tighten a cortical screw without causing any stripping.

METHODS

Twenty-five residents and 8 attending surgeons from an orthopaedic residency program tightened cortical screws in a synthetic bone model with a digital torque screwdriver using 3 different techniques: percutaneous; open, dominant hand; and open, nondominant hand. The residents then participated in a training protocol during which each tightened additional screws while receiving real-time torque feedback. During training, the residents targeted 50% to 70% of the stripping torque for each screw. They were assessed at baseline, immediately after training, and at 12 to 15 weeks after training. During each assessment, the percentage of screws that were tightened in the target range and the percentage of stripped screws were recorded. The costs of the training protocol were assessed.

RESULTS

After training, all of the residents tightened screws with lower insertional torque compared with their baseline, but only the senior residents tightened more screws in the target range and stripped fewer screws. The attending surgeons, when compared with the residents at baseline, tightened more screws in the target range and tended to strip fewer screws, but these differences were absent at final testing. Costs included $1,927 for durable equipment and an estimated $74 per resident per training session for consumable goods.

CONCLUSIONS

The senior residents inserted more screws in the target range and stripped fewer screws after participating in this training protocol, but the junior residents did not show significant improvement. Implementation of this training protocol for all residents may improve clinical performance but, because our sample size was limited, additional study is required to assess skill transfer to clinical practice.

CLINICAL RELEVANCE

Cortical-screw tightening is a fundamental skill in orthopaedics, and completion of this torque-directed training protocol may accelerate residents' skill acquisition.

Achievable accuracy of hip screw holding power estimation by insertion torque measurement

BACKGROUND

To ensure stability of proximal femoral fractures, the hip screw must firmly engage into the femoral head. Some studies suggested that screw holding power into trabecular bone could be evaluated, intraoperatively, through measurement of screw insertion torque. However, those studies used synthetic bone, instead of trabecular bone, as host material or they did not evaluate accuracy of predictions. We determined prediction accuracy, also assessing the impact of screw design and host material.

METHODS

We measured, under highly-repeatable experimental conditions, disregarding clinical procedure complexities, insertion torque and pullout strength of four screw designs, both in 120 synthetic and 80 trabecular bone specimens of variable density. For both host materials, we calculated the root-mean-square error and the mean-absolute-percentage error of predictions based on the best fitting model of torque-pullout data, in both single-screw and merged dataset.

FINDINGS

Predictions based on screw-specific regression models were the most accurate. Host material impacts on prediction accuracy: the replacement of synthetic with trabecular bone decreased both root-mean-square errors, from 0.54 ÷ 0.76 kN to 0.21 ÷ 0.40 kN, and mean-absolute-percentage errors, from 14 ÷ 21% to 10 ÷ 12%. However, holding power predicted on low insertion torque remained inaccurate, with errors up to 40% for torques below 1 Nm.

INTERPRETATION

In poor-quality trabecular bone, tissue inhomogeneities likely affect pullout strength and insertion torque to different extents, limiting the predictive power of the latter. This bias decreases when the screw engages good-quality bone. Under this condition, predictions become more accurate although this result must be confirmed by close in-vitro simulation of the clinical procedure.

Automated Bone Screw Tightening to Adaptive Levels of Stripping Torque

OBJECTIVE

To use relationships between tightening parameters, related to bone quality, to develop an automated system that determines and controls the level of screw tightening.

METHODS

An algorithm relating current at head contact (IHC) to current at construct failure (Imax) was developed. The algorithm was used to trigger cessation of screw insertion at a predefined tightening level, in real time, between head contact and maximum current. The ability of the device to stop at the predefined level was assessed.

RESULTS

The mean (±SD) current at which screw insertion ceased was calculated to be [51.47 ± 9.75% × (Imax - IHC)] + IHC, with no premature bone failures.

CONCLUSIONS

A smart screwdriver was developed that uses the current from the motor driving the screw to predict the current at which the screw will strip the bone threads. The device was implemented and was able to achieve motor shut-off and cease tightening at a predefined threshold, with no premature bone failures.

Cancellous Screws Are Biomechanically Superior to Cortical Screws in Metaphyseal Bone

Cancellous screws are designed to optimize fixation in metaphyseal bone environments; however, certain clinical situations may require the substitution of cortical screws for use in cancellous bone, such as anatomic constraints, fragment size, or available instrumentation. This study compares the biomechanical properties of commercially available cortical and cancellous screw designs in a synthetic model representing various bone densities. Commercially available, fully threaded, 4.0-mm outer-diameter cortical and cancellous screws were tested in terms of pullout strength and maximum insertion torque in standard-density and osteoporotic cancellous bone models. Pullout strength and maximum insertion torque were both found to be greater for cancellous screws than cortical screws in all synthetic densities tested. The magnitude of difference in pullout strength between cortical and cancellous screws increased with decreasing synthetic bone density. Screw displacement prior to failure and total energy absorbed during pullout strength testing were also significantly greater for cancellous screws in osteoporotic models. Stiffness was greater for cancellous screws in standard and osteoporotic models. Cancellous screws have biomechanical advantages over cortical screws when used in metaphyseal bone, implying the ability to both achieve greater compression and resist displacement at the screw-plate interface. Surgeons should preferentially use cancellous over cortical screws in metaphyseal environments where cortical bone is insufficient for fixation. [Orthopedics.2016; 39(5):e828-e832.].

Effect of Real-Time Feedback on Screw Placement Into Synthetic Cancellous Bone

OBJECTIVES

The objective of this study is to evaluate whether real-time torque feedback may reduce the occurrence of stripping when inserting nonlocking screws through fracture plates into synthetic cancellous bone.

METHODS

Five attending orthopaedic surgeons and 5 senior level orthopaedic residents inserted 8 screws in each phase. In phase I, screws were inserted without feedback simulating conventional techniques. In phase II, screws were driven with visual torque feedback. In phase III, screws were again inserted with conventional techniques. Comparison of these 3 phases with respect to screw insertion torque, surgeon rank, and perception of stripping was used to establish the effects of feedback.

RESULTS

Seventy-three of 239 screws resulted in stripping. During the first phase, no feedback was provided and the overall strip rate was 41.8%; this decreased to 15% with visual feedback (P < 0.001) and returned to 35% when repeated without feedback. With feedback, a lower average torque was applied over a narrower torque distribution. Residents stripped 40.8% of screws compared with 20.2% for attending surgeons. Surgeons were poor at perceiving whether they stripped.

CONCLUSIONS

Prevention and identification of stripping is influenced by surgeon perception of tactile sensation. This is significantly improved with utilization of real-time visual feedback of a torque versus roll curve. This concept of real-time feedback seems beneficial toward performance in synthetic cancellous bone and may lead to improved fixation in cancellous bone in a surgical setting.

Time-elapsed screw insertion with microCT imaging

Time-elapsed analysis of bone is an innovative technique that uses sequential image data to analyze bone mechanics under a given loading regime. This paper presents the development of a novel device capable of performing step-wise screw insertion into excised bone specimens, within the microCT environment, whilst simultaneously recording insertion torque, compression under the screw head and rotation angle. The system is computer controlled and screw insertion is performed in incremental steps of insertion torque. A series of screw insertion tests to failure were performed (n=21) to establish a relationship between the torque at head contact and stripping torque (R(2)=0.89). The test-device was then used to perform step-wise screw insertion, stopping at intervals of 20%, 40%, 60% and 80% between screw head contact and screw stripping. Image data-sets were acquired at each of these time-points as well as at head contact and post-failure. Examination of the image data revealed the trabecular deformation as a result of increased insertion torque was restricted to within 1mm of the outer diameter of the screw thread. Minimal deformation occurred prior to the step between the 80% time-point and post-failure. The device presented has allowed, for the first time, visualization of the micro-mechanical response in the peri-implant bone with increased tightening torque. Further testing on more samples is expected to increase our understanding of the effects of increased tightening torque at the micro-structural level, and the failure mechanisms of trabeculae.

"Turn-of-the-Nut" Method Is Not Appropriate for Use in Cancellous Bone

OBJECTIVE

The level to which bone screws are tightened is determined subjectively by the operating surgeon. It is likely that the tactile feedback that surgeons rely on is based on localized tissue yielding, which may predispose the screw-bone interface to failure. A limited number of studies have investigated the ratio between clinical tightening torque and stripping torque. The purpose of this study was to measure, for the first time, the ratio between yield torque (T yield) and stripping torque (T max) during screw insertion into the cancellous bone and to compare these torques with clinical levels of tightening reported in the literature. Additionally, a rotational limit was investigated as a potential end point for screw insertion in cancellous bone.

METHODS

A 6.5-mm outer diameter commercial cancellous bone screw was inserted into human femoral head specimens (n = 89). Screws were inserted to failure, while recording insertion torque, compression under the screw head, and rotation angle.

RESULTS

The median, interquartile ranges, and coefficient of variation were calculated for each of the following parameters: T yield, T max, T yield/T max, slope, T plateau, and rotation angle. The median ratio of T yield/T max and rotation angle was 85.45% and 96.5 degrees, respectively. The coefficient of variation was greatest for the rotation angle compared with the ratio of T yield/T max (0.37 vs. 0.12).

CONCLUSIONS

The detection of yield may be a more precise method than the rotation angle in cancellous bone; however, bone-screw constructs that exhibit a T yield close to T max may be more susceptible to stripping during insertion. Future work can identify factors that influence the ratio of T yield/T max may help to reduce the incidence of screw stripping.

Can high-friction intraannular material increase screw pullout strength in osteoporotic bone?

BACKGROUND

Osteoporotic bone brings unique challenges to orthopaedic surgery, including a higher likelihood of problematic screw stripping in cancellous bone. Currently, there are limited options to satisfactorily repair stripped screws. Additionally, nonstripped screws hold with less purchase in osteoporotic bone.

QUESTIONS/PURPOSES

This study attempts to answer the following questions: (1) Does high-friction intraannular (HFIA) augmentation increase pullout strength in osteoporotic and in severely osteoporotic bone; and (2) can HFIA repair stripped bone thread in osteoporotic and severely osteoporotic bone?

METHODS

We measured screw pullout strength using a synthetic bone model in three groups: (1) predrilled nonstripped control holes as controls; (2) predrilled nonstripped augmented with HFIA; and (3) predrilled stripped holes repaired with HFIA. We tested this in osteoporotic and severely osteoporotic synthetic bone for a total of six test groups. We measured screw pullout force using an electromechanical tensile-testing machine comparing pullout force between the test groups and controls.

RESULTS

HFIA augmentation did not increase pullout force compared with the control group in the osteoporotic bone model (489 ± 175 versus 607 ± 76, respectively; effect size = 0.94 [95% confidence interval {CI}, -1.75 to 0.08], p = 0.06). However, in severely osteoporotic cancellous bone that was augmented, the HFIA material generated more pullout force than the control (51 ± 18 versus 35 ± 16, respectively; effect size = 0.94 [95% CI, -0.02 to 1.82], p = 0.05). In stripped holes, HFIA partially restored pullout strength but remained weaker than controls in both osteoporotic and severely osteoporotic bone models (osteoporotic: 320 ± 59 versus 607 ± 76, respectively; effect size = -4.28 [95% CI, -5.57 to -2.51], p < 0.001; severely osteoporotic: 21 ± 8 versus 35 ± 16, respectively; effect size = -1.13 [95% CI, -2.0 to 0.12], p = 0.027).

CONCLUSIONS

HFIA effectively augmented severely osteoporotic bone for screw purchase, but this effect was not seen for osteoporotic bone. In a model simulating both osteoporotic and severely osteoporotic bone, we found that HFIA can be used to repair stripped screw holes, but the resulting construct remains weaker than nonstripped controls.

CLINICAL RELEVANCE

The HFIA material looks promising as a potential solution to stripped screws in osteoporotic bone. However, this material has yet to be tested in human bone. Furthermore, the fine mesh material could be damaged by autoclaving and could break off in vivo causing unknown tissue reactions. We recommend additional testing in a living animal model to better understand how living bone will react to the HFIA material.

Topical review: locking plate technology in foot and ankle surgery

The use of locking plate technology in foot and ankle surgery has increased over the last decade. Reported applications include fracture repair, deformity correction, and arthrodesis. There is limited evidence, however, to guide clinicians with regard to the appropriate and optimal use of this technology. This work aims to examine the current biomechanical and clinical evidence comparing locking construct technology to other forms of fixation in the field of foot and ankle surgery.