A New Method of In Vitro Wear Assessment of the UHMWPE Tibial Insert in Total Knee Replacement

Computational wear prediction of insert conformity and material on mobile-bearing unicompartmental knee arthroplasty

Objectives

Unicompartmental knee arthroplasty (UKA) is an alternative to total knee arthroplasty with isolated medial or lateral compartment osteoarthritis. However, polyethylene wear can significantly reduce the lifespan of UKA. Different bearing designs and materials for UKA have been developed to change the rate of polyethylene wear. Therefore, the objective of this study is to investigate the effect of insert conformity and material on the predicted wear in mobile-bearing UKA using a previously developed computational wear method.

Methods

Two different designs were tested with the same femoral component under identical kinematic input: anatomy mimetic design (AMD) and conforming design inserts with different conformity levels. The insert materials were standard or crosslinked ultra-high-molecular-weight polyethylene (UHMWPE). We evaluated the contact pressure, contact area, wear rate, wear depth, and volumetric wear under gait cycle loading conditions.

Results

Conforming design inserts had the lower contact pressure and larger contact area. However, they also had the higher wear rate and volumetric wear. The improved wear performance was found with AMD inserts. In addition, the computationally predicted volumetric wear of crosslinked UHMWPE inserts was less than half that of standard UHMWPE inserts.

Conclusion

Our results showed that increasing conformity may not be the sole predictor of wear performance; highly crosslinked mobile-bearing polyethylene inserts can also provide improvement in wear performance. These results provide improvements in design and materials to reduce wear in mobile-bearing UKA.

Cite this article: Bone Joint Res 2019;8:563–569.

A Critical Analysis of TKR In Vitro Wear Tests Considering Predicted Knee Joint Loads

Detailed knowledge about loading of the knee joint is essential for preclinical testing of total knee replacement. Direct measurement of joint reaction forces is generally not feasible in a clinical setting; non-invasive methods based on musculoskeletal modelling should therefore be considered as a valid alternative to the standards guidelines. The aim of this paper is to investigate the possibility of using knee joint forces calculated through musculoskeletal modelling software for developing an in vitro wear assessment protocol by using a knee wear simulator. In particular, in this work we preliminarily show a comparison of the predicted knee joint forces (in silico) during the gait with those obtained from the ISO 14243-1/3 and with those measured in vivo by other authors. Subsequently, we compare the wear results obtained from a knee wear joint simulator loaded by calculated forces in correspondence to the “normal gait” kinematics with those obtained in correspondence to the loads imposed by the ISO. The obtained results show that even if the predicted load profiles are not totally in good agreement with the loads deriving from ISO standards and from in vivo measurements, they can be useful for in vitro wear tests, since the results obtained from the simulator in terms of wear are in agreement with the literature data.

The influence of simulator input conditions on the wear of total knee replacements: An experimental and computational study

Advancements in knee replacement design, material and sterilisation processes have provided improved clinical results. However, surface wear of the polyethylene leading to osteolysis is still considered the longer-term risk factor. Experimental wear simulation is an established method for evaluating the wear performance of total joint replacements. The aim of this study was to investigate the influence of simulation input conditions, specifically input kinematic magnitudes, waveforms and directions of motion and position of the femoral centre of rotation, on the wear performance of a fixed-bearing total knee replacement through a combined experimental and computational approach. Studies were completed using conventional and moderately cross-linked polyethylene to determine whether the influence of these simulation input conditions varied with material. The position of the femoral centre of rotation and the input kinematics were shown to have a significant influence on the wear rates. Similar trends were shown for both the conventional and moderately cross-linked polyethylene materials, although lower wear rates were found for the moderately cross-linked polyethylene due to the higher level of cross-linking. The most important factor influencing the wear was the position of the relative contact point at the femoral component and tibial insert interface. This was dependent on the combination of input displacement magnitudes, waveforms, direction of motion and femoral centre of rotation. This study provides further evidence that in order to study variables such as design and material in total knee replacement, it is important to carefully control knee simulation conditions. This can be more effectively achieved through the use of displacement control simulation.

Toward the interpretation of the combined effect of size and body weight on the tribological performance of total knee prostheses

PURPOSE

The research questions of the present study were: (1) Is total knee prosthesis wear behaviour influenced by implant size, body weight and their combined effect? (2) Are these findings significant and helpful from a clinical point of view?

METHODS

Two very different sizes of the same total knee prosthesis (TKP), previously tested with ISO 14243 parameters, were tested on a knee simulator for a further two million cycles using a modified ISO 14243 load waveform. Roughness examination was performed on the metallic components. Gravimetric and micro-Raman spectroscopic analyses were carried out on the polyethylene inserts.

RESULTS

The average volumetric mass loss was 69 ± 3 mm(3) and 88 ± 4 mm(3) for smaller and bigger size, respectively. Bigger TKPs are little influenced by an increased load, while the wear trend of the smaller TKP showed a redoubled slope, and more significant morphology changes were observed. However, the two sizes seem to behave similarly when subjected to a load increase of 15 %; the slope of the volumetric mass loss trend was comparable for the two sets of inserts, which did not appear significantly different also at the molecular level. Roughness average parameters of the lateral femoral condyle support this evidence.

CONCLUSIONS

It can be asserted that the body weight and implant size are relevant to the understanding of TKP wear behaviour. A post-implantation body weight increase in a patient with smaller knee dimensions could results in more critical effects on prosthesis long-term performance.

The influence of kinematic conditions and design on the wear of patella-femoral replacements

The success rate of patella-femoral arthroplasty varies between 44% and 90% in 17 years of follow-up. Several studies have been performed previously for assessing the surface wear in the patella-femoral joint. However, they have not included all six degrees of freedom. The aim of this study was to develop a six-axis patella-femoral joint simulator to assess the wear rate for two patellae designs (round and oval dome) at different kinematic conditions. An increase in patellar rotation from 1° to 4° led to a significantly (p<0.049) increased wear rate of round dome from 8.6 mm³/million cycles to 12.3 mm³/million cycles. The wear rate for oval dome increased from 6.3 mm³/million cycles to 14.5 mm³/million cycles. However, the increase was nonsignificant (p>0.08). The increase in wear rate was likely due to the higher cross shear. A decrease in patellar medial lateral displacement from passive to constrained resulted in a nonsignificant reduction in wear (p>0.06). There was no significant difference in wear rate between the two patellae designs (p>0.28). The volumetric wear under all conditions was positively correlated with the level of passive patellar tilt (rho>0.8). This is the first report of preclinical wear simulation of patella-femoral joint in a six-axis simulator under different kinematic conditions.

Third-body abrasive wear of tibial polyethylene inserts combined with metallic and ceramic femoral components in a knee simulator study

AIM

Total knee arthroplasties have reached a high grade of quality and safety, but most often fail because of aseptic implant loosening caused by polyethylene wear debris. Wear is generated at the articulating surfaces, e.g. caused by third-body particles. The objective of this experimental study was to determine the wear of tibial polyethylene inserts combined with metallic and ceramic femoral components under third-body wear conditions initiated by bone cement particles.


METHODS AND MATERIALS

Wear testing using a cemented unconstrained bicondylar knee endoprosthesis (Multigen Plus CR knee system) was performed in a knee wear simulator. Tibial polyethylene inserts were combined with the identical femoral component design, but made of two different materials (cobalt-chromium and ceramic). Bone cement debris including zirconium oxide particles was added every 500,000 cycles between the articulating surfaces. After 5 million load cycles, the amount of wear was determined gravimetrically and compared with results from standard wear test conditions. The surfaces of tibial inserts were also analyzed.


RESULTS

The average gravimetrical wear of the tibial polyethylene inserts in combination with 
cobalt-chromium and ceramic femoral components under third-body wear conditions amounted to 31.88 ± 4.53 mg and 13.06 ± 1.88 mg after 5 million cycles, respectively, and was higher than under standard wear test conditions in both cases.


CONCLUSIONS

The wear simulator test demonstrates that wear of polyethylene inserts under third-body wear conditions, in combination with ceramic femoral components, was significantly lower than with metallic femoral components.

Mobile or fixed unicompartmental knee prostheses? In-vitro wear assessments to solve this dilemma

The unicompartmental knee prosthesis is an attractive alternative to total knee arthroplasty. Current UKP devices can be subdivided into two groups based on different design principles: fixed bearing knees, where the ultra-high molecular weight polyethylene meniscal component snap or press fits into the tibial tray, and mobile bearing designs which facilitate movement of the insert relative to the tray. The present study was aimed at comparing the in-vitro wear behaviour of fixed and mobile unicompartmental knee menisci under two configurations: the femoral components were cemented into a custom-made metallic block or, as a novelty of the present study, into a synthetic femur (i.e. under conditions which should better reproduce the in-vivo behaviour). Analyses were performed using a displacement-control knee wear simulator with "three-plus-one" stations. All the kinematics tests were set in accordance with the ISO 14243-1,2,3. Fixed and mobile polyethylene menisci showed a different wear behaviour: the fixation-frame influenced directional load transfer through each component in a qualitative and quantitative way. In fact, gravimetric results showed that under the metal block holder fixation, mobile components worn more than fixed components (weight losses of 8.7±2.0 mg and 2.6±1.09 mg, respectively); on the other hand, under the synthetic femur configuration, differences in wear behaviour were less pronounced and mobile menisci underwent a slightly lower weight loss than fixed components (4.5±2.2 mg vs. 6.7±1.4 mg). This different trend was explained in relation to the kinematic schemes of the two fixation methods. Raman spectroscopy, used to evaluate the UHMWPE crystallinity changes induced by mechanical stress, showed that mobile menisci specimens were more affected than the fixed components in both their superior and inferior surfaces, independent of the fixation-frame. In conclusion, if tested under conditions which should better reproduce the in-vivo behaviour, mobile UKPs did not show a worse wear behaviour than fixed components in terms of weight losses, although UHMWPE changes at the molecular scale could be detrimental.

Crosslinked polyethylene in knee arthroplasty: a simulator study evaluating the positive influence on the tribocontact area in the fixed-bearing knee

BACKGROUND

Crosslinked polyethylene (XPE) was developed to reduce the wear rate in hip as well as knee arthroplasty. The crosslinking process reduces the mechanical properties of ultra-high-molecular-weight polyethylene (UHMWPE), particularly its fatigue strength. UHMWPE fatigue occurs more frequently in the knee than in the hip joint due to its changing tribocontact areas (TCAs) combined with high weight bearing. This is why XPE is still controversially discussed for use in total knee arthroplasty. Therefore, the potential advantage of using XPE in the knee was analysed in a simulator study with a focus on potential fatigue wear mechanisms.

METHODS

Three different kinds of XPE and one conventional UHMWPE were tested over 5 million cycles in fixed-bearing knee designs. The TCAs were examined by replicas, and their extent was measured. The wear mechanism was analysed by scanning electron microscopy.

RESULTS

The extent of the TCAs was less than 5% for all XPEs, whereas 35% for the conventional UHMWPE. Fatigue wear mechanisms were not observed.

CONCLUSION

The measured small extent of the TCAs as a predictor of a low wear rate without any fatigue wear mechanism shows a possible advantage for the use of XPE even in knee arthroplasty.

Polyethylene insert damage in unicondylar knee replacement: a comparison of in vivo function and in vitro simulation

Modification of knee joint wear simulation methods has included 'anatomic attachment' of unicondylar knee replacements (UKR) onto synthetic femurs with material properties and morphology similar to human femurs. The present study assesses the effect of such modification by comparing the damage patterns on UKR polyethylene inserts after in vitro simulation using standard and modified simulation methods with those on inserts retrieved after in vivo function. Three groups of UKR inserts were evaluated after retrieval (Explant Group, n = 17) or after knee joint wear simulation with the components attached to standard metal blocks (Standard Group, n = 6) or synthetic femurs (Anatomic Group, n = 6). All UKR had similar non-conforming articular surfaces. Articular damage patterns (mode, frequency, and area) were quantified using digital image photogrammetry. Although some common damage modes were noted, knee joint wear simulation with standard or 'anatomic' attachment did not generate damage pattern sizes similar to the explanted UKR. A focal damage pattern consistent with contact between the metal femoral articular surface and the polyethylene inserts was evident on all inserts, but only the Explant Group had evidence of dispersed damage dominated by abrasive modes. Synthetic femurs added complexity to the wear simulation without generating wear patterns substantially more similar to those observed on retrieved inserts.