Mechanical properties of an elastically deformable cervical spine implant

Anterior cervical surgery is widely accepted and time-tested surgical procedure for treating cervical radiculopathy and myelopathy. However, there is concern about the high adjacent segment degeneration rate and implant subsidence after the surgery using the traditional polyetheretherketone cage. Thus, we creatively designed a polyurethane cervical implant that can continuous load-sharing through elastic deformation and decrease postoperative stress concentration at adjacent segments. In this study, the design rationality and safety of this novel implant was evaluated based on several mechanical parameters including compression test, creeping test, push-out test and subsidence test. The results showed that the novel cervical implant remained intact under the compressive axial load of 8000 N and continues to maintained the elastic deformation phase. The minimum push-out load of the implant was 181.17 N, which was significantly higher than the maximum compressive shear load of 20 N experienced by a normal human cervical intervertebral disc. Besides, the creep recovery behaviour of the implant closely resembled what has been reported for natural intervertebral discs and clinically applied cervical devices in literature. Under the load of simulating daily activities of the cervical spine, the implant longitudinal displacement was only 0.54 mm. In conclusion, this study showed that the current design of the elastically deformable implant was reasonable and stable to fulfil the mechanical requirements of a cervical prosthesis under physiological loads. After a more comprehensive understanding of bone formation and stress distribution after implantation, this cervical implant is promising to be applied to certain patients in clinical practice.

Experimental Study to Evaluate the Wear Performance of UHMWPE and XLPE Material for Orthopedics Application

The main objective of this study is to perform an abrasive wear resistance study of UMHWPE and XLPE by using different grades of abrasive paper (grade 100 (190 µm), grade 220 (50 µm), and grade 400 (40 µm)) with minor (10 N) and major (15 N) loading conditions. In this article, wear performance of the UMHWPE and XLPE materials compared to the bio-tribological data as reported earlier in the clinical studies has been investigated. The experimental result shows that the loss of materials for the XLPE was much higher than the UHMWPE under similar loading conditions. UHMWPE shows a 34% reduction in wear at minor loading conditions and a 53% reduction in wear at major loading conditions. From experimental results it was concluded that Cross-link PE has better wear resistance than UHMWPE in minor wear conditions, whereas UHMWPE shows better wear resistance under major loading conditions. Based upon these results, UHMWPE and XLPE have been recommended for use as bearing materials in orthopedics. The experimental results of this study were validated using results from the available literature.

The influence of the viscoelastic property of polycarbonate urethane as an artificial disc core material under various physiological motions at the L4-L5 level

Intervertebral disc (IVD) degeneration is one of the musculoskeletal disorders due to the Degenerative Disc Disease (DDD), that cause low back pain (LBP) and leads to a reduced range of motion. Spinal fusion and arthroplasty are the other surgical procedures that could replace the disc affected by DDD against artificial disc replacement (ADR). This study aims to analyse the biomechanical behaviour of proposed core material as Polycarbonate Urethane (PCU) in the L4-L5 lumbar segment for ADR with Ti-6Al-4V and Co-28Cr-6M as endplate materials and compare it to the performance of an ultra-high molecular weight polyethylene (UHMWPE) core. Finite element methods have been approached to measure the overall stress distribution along with other physiological motions like Flexion (FLEX), Extension (EXT), Axial rotation (AR) and Lateral bending (LB), respectively. Preload of 450 N compressive load, 8 N-m for Flex, 6 N-m for EXT, 6 N-m for AR and 4 N-m for LB are applied. It could be concluded that Ti-6Al-4V - PCU and Co-28Cr-6M - PCU is the best composition for the ADR for the L4-L5 level.

A 3D-transient elastohydrodynamic lubrication hip implant model to compare ultra high molecular weight polyethylene with more compliant polycarbonate polyurethane acetabular cups

Wear remains a significant challenge in the design of orthopedic implants such as total hip replacements. Early elastohydrodynamic lubrication modeling has predicted thicker lubrication films in hip replacement designs with compliant polycarbonate polyurethane (PCU) bearing materials compared to stiffer materials like ultra-high molecular weight polyethylene (UHMWPE). The predicted thicker lubrication films suggest improved friction and wear performance. However, when compared to the model predictions, experimental wear studies showed mixed results. The mismatch between the model and experimental results may lie in the simplifying assumptions of the early models such as: steady state conditions, one dimensional rotation and loading, and high viscosities. This study applies a 3D-transient elastohydrodynamic model based on an ISO standard gait cycle to better understand the interaction between material stiffness and film thickness in total hip arthroplasty material couples. Similar to previous, simplified models, we show that the average and central film thickness of PCU (∼0.4μm) is higher than that of UHMWPE (∼0.2μm). However, in the 3D-transient model, the film thickness distribution was largely asymmetric and the minimum film thickness occurred outside of the central axis. Although the overall film thickness of PCU was higher than UHMWPE, the minimum film thickness of PCU was lower than UHMPWE for the majority of the gait cycle. The minimum film thickness of PCU also had a larger range throughout the gait cycle. Both materials were found to be operating between boundary and mixed lubrication regimes. This 3D-transient model reveals a more nuanced interaction between bearing material stiffness and film thickness that supports the mixed results found in experimental wear studies of PCU hip implant designs.

The MOVE-C Cervical Artificial Disc - Design, Materials, Mechanical Safety

Purpose

There are various cervical disc prostheses on the market today. They can be subdivided into implants with a ball-and-socket design and implants with a flexible core, which is captured between the implant endplates and sealed using various sheaths. Implants with an articulating surface are mostly metal-on-metal or metal-on-UHMWPE designs and, thus, do not allow for axial damping. The aim of this study is to provide mechanical safety and performance data of the MOVE-C cervical disc prosthesis which combines both an articulating surface and a flexible core.

Materials and Methods

MOVE-C consists of a cranial and caudal metal plate made of TiAl6V4. The cranial plate is TiNbN coated on its articulating surface. The caudal plate has a fixed polycarbonate-urethane (PCU) core. The TiNbN coating is meant to optimize the wear behavior of the titanium endplate, whereas the PCU core is meant to allow for a reversible axial deformation, a pre-defined neutral zone and a progressive load-deformation curve in all planes.

Results

Various standard testing procedures (for example, ISO 18192–1 and ASTM F2364) and non-standard mechanical tests were carried out to prove the implant’s mechanical safety. Due to the new implant design, wear and creep testing was deemed most important. The wear rate for the PCU was in maximum 1.54 mg per million cycles. This value was within the range of the UHMWPE wear rates reported for other cervical disc prostheses (0.53 to 2.59 mg/million cycles). Also in the creep-relaxation test, a qualitatively physiological behavior was shown with a certain amount of remaining deformation but no failure.

Conclusion

The mechanical safety of the MOVE-C cervical disc prosthesis was shown to be comparable to other cervical disc prostheses. Since PCU wear particles were elsewhere shown to be less bioactive than cross-linked UHMWPE particles, wear-related failure in vivo may be less frequent compared to other prostheses. This, however, will have to be shown in further studies.

3D printing of high-strength, porous, elastomeric structures to promote tissue integration of implants

Despite advances in biomaterials research, there is no ideal device for replacing weight-bearing soft tissues like menisci or intervertebral discs due to poor integration with tissues and mechanical property mismatch. Designing an implant with a soft and porous tissue-contacting structure using a material conducive to cell attachment and growth could potentially address these limitations. Polycarbonate urethane (PCU) is a soft and tough biocompatible material that can be 3D printed into porous structures with controlled pore sizes. Porous biomaterials of appropriate chemistries can support cell proliferation and tissue ingrowth, but their optimal design parameters remain unclear. To investigate this, porous PCU structures were 3D-printed in a crosshatch pattern with a range of in-plane pore sizes (0 to 800 μm) forming fully interconnected porous networks. Printed porous structures had ultimate tensile strengths ranging from 1.9 to 11.6 MPa, strains to failure ranging from 300 to 486%, Young's moduli ranging from 0.85 to 12.42 MPa, and porosity ranging from 13 to 71%. These porous networks can be loaded with hydrogels, such as collagen gels, to provide additional biological support for cells. Bare PCU structures and collagen-hydrogel-filled porous PCU support robust NIH/3T3 fibroblast cell line proliferation over 14 days for all pore sizes. Results highlight PCU's potential in the development of tissue-integrating medical implants.

Three-year results of a polycarbonate urethane acetabular bearing in total hip arthroplasty

BACKGROUND

Polycarbonate urethane (PCU) is a bearing surface with a lower modulus of elasticity than polyethylene or ceramic and is thought to more closely replicate the tribology of native hyaline cartilage. The purpose of this study was to determine the clinical outcomes with the use of PCU in elective total hip arthroplasty (THA).

METHODS

We carried out a prospective observational study in which 157 patients underwent elective THA with a metal-on-PCU hip system. Patients had radiographic follow-up at 6 months and 3 years after surgery. Oxford Hip Scores and EuroQol scores were obtained annually and Harris Hip Scores were obtained at 6 months and 3 years after surgery.

RESULTS

180 hips were implanted, of which, 149 hips reached 3-year review with no revisions. There was an increase in Harris Hip Scores, Oxford Hip Scores and EuroQol scores (p < 0.001). 12 patients (12 hips) reported painless hip squeaking. There were no dislocations and no other adverse events were reported.

CONCLUSION

Our results showed satisfactory survivorship and improvements in patient reported outcomes with metal on PCU THA. Long-term data are still being collected to confirm these findings. We recommend further tribological research into the squeaking phenomenon we observed.

Lessons learnt from early failure of a patient trial with a polymer-on-polymer resurfacing hip arthroplasty

Background and purpose - Hip resurfacing (HR) is a treatment option promoted for hip arthritis in young and active patients. However, adverse reactions to metal are a concern and the search for non-metallic bearing options proceeds. We present the first clinical study performed in patients using a newly developed hydrophilic polymer-on-polymer hip resurfacing device. Patients and methods - After performing extensive hip simulator tests, biocompatibility testing and animal tests (ISO 14242-1,3; 10993-3,4,5,10,11), approval was obtained from the IRB committee to enroll 15 patients in the first clinical study in humans using this experimental polymer-on-polymer hip resurfacing device. All surgeries were done by 2 experienced hip resurfacing surgeons. Clinical scores and standard radiographs as well as routine MRIs were obtained at regular intervals. Results - The surgical technique proved feasible with successful implantation of the new device using PMMA cement fixation on both sides without complications. Postoperative imaging revealed a well-positioned and well-fixed polymer resurfacing hip arthroplasty in all 4 initial cases. All 4 patients were free of pain and had good function for the first 2 months. However, in all 4 cases early cup loosening occurred between 8 and 11 weeks after surgery, necessitating immediate closure of the study. All 4 patients had a reoperation and were revised to a conventional THA. Retrieval analyses confirmed early cup loosening at the implant-cement interface in all 4 cases. The femoral components remained well attached to the cement. The periprosthetic tissues showed only small amounts of polymeric wear debris and there was only a very mild inflammatory reaction to this. Interpretation - Early cup loosening mandated a premature arrest of this study. After additional laboratory testing this failure mode was found to be the result of a small, yet measurable contraction in the cup size after exposing these implants to biological fluid divalent ion fluctuations in vivo. Currently used preclinical tests had failed to detect this failure mechanism. Modification of the polymer is essential to overcome these problems and before the potential of a polymer-on-polymer resurfacing arthroplasty may be further evaluated in patients.

The use of polycarbonate-urethane as an acetabular shell bearing surface: a 5-year prospective study

AIM

To evaluate the clinical performance of a polycarbonate-urethane liner as a bearing material inside a cobalt-chrome acetabular shell.

METHODS

Between December 2007 and July 2011, this material combination was used in 27 total hip replacement patients, most of whom had an indication of osteoarthritis. This report focuses on the first 5-year results of the clinical use of this material combination in the TriboFit® Hip System.

RESULTS

Mean Harris Hip Score showed significant improvement from 40 to 86 after 5 years, similar to studies in the literature. No adverse events - revisions or complications - or disadvantages that have been reported for other total hip materials were observed over the 5-year period. The radiographs showed no signs of wear, migration or loosening of the implants.

CONCLUSIONS

These early results indicate this new material combination offers promise as a safe and effective alternative bearing material for use in total hip systems. Further clinical trials are necessary to reconfirm these findings.

Retrieval analysis of a failed TriboFit polycarbonate urethane acetabular buffer

The purpose of this research was to determine the failure mechanisms and damage features of a TriboFit acetabular buffer implanted directly against a native, prepared acetabulum which was revised after 11months. Retrieval analyses were carried out via light microscopy, gravimetric wear assessment, and observer scoring of visible damage features on the buffer. The volume of material abraded from the backside of the buffer was estimated via three-dimensional reconstruction using a laser scanner. Scanning electron microscopy was used to confirm damage features and mechanisms. Severe abrasion to the backside of the buffer was the primary damage feature, while stippling damage was seen on the articular surface of the buffer. Material loss due to backside abrasion was approximated to be between 0.13360.085 g (gravimetric analyses) and 0.19360.053 g (three-dimensional reconstruction). Implantation of the TriboFit buffer against the patient's native acetabulum without a metal backing allowed for significant movement of the buffer against the bone, resulting in the abrasion seen on this implant. The stippling damage on the articular surface indicates an adhesive wear mechanism which exacerbates movement of the buffer against the acetabulum, thereby increasing backside abrasion.

Quantification of in vitro wear of a synthetic meniscus implant using gravimetric and micro-CT measurements

A synthetic meniscus implant was recently developed for the treatment of patients with mild to moderate osteoarthritis with knee pain associated with medial joint overload. The implant is distinctively different from most orthopedic implants in its pliable construction, and non-anchored design, which enables implantation through a mini-arthrotomy without disruption to the bone, cartilage, and ligaments. Due to these features, it is important to show that the material and design can withstand knee joint conditions. This study evaluated the long-term performance of this device by simulating loading for a total of 5 million gait cycles (Mc), corresponding to approximately five years of service in-vivo. All five implants remained in good condition and did not dislodge from the joint space during the simulation. Mild abrasion was detected by electron microscopy, but µ-CT scans of the implants confirmed that the damage was confined to the superficial surfaces. The average gravimetric wear rate was 14.5 mg/Mc, whereas volumetric changes in reconstructed µ-CT scans point to an average wear rate of 15.76 mm(3)/Mc (18.8 mg/Mc). Particles isolated from the lubricant had average diameter of 15 µm. The wear performance of this polycarbonate-urethane meniscus implant concept under ISO-14243 loading conditions is encouraging.

The use of polyurethane materials in the surgery of the spine: a review

BACKGROUND CONTEXT

The spine contains intervertebral discs and the interspinous and longitudinal ligaments. These structures are elastomeric or viscoelastic in their mechanical properties and serve to allow and control the movement of the bony elements of the spine. The use of metallic or hard polymeric devices to replace the intervertebral discs and the creation of fusion masses to replace discs and/or vertebral bodies changes the load transfer characteristics of the spine and the range of motion of segments of the spine.

PURPOSE

The purpose of the study was to survey the literature, regulatory information available on the Web, and industry-reported device development found on the Web to ascertain the usage and outcomes of the use of polyurethane polymers in the design and clinical use of devices for spine surgery.

STUDY DESIGN/SETTING

A systematic review of the available information from all sources concerning the subject materials' usage in spinal devices was conducted.

METHODS

A search of the peer-reviewed literature combining spinal surgery with polyurethane or specific types and trade names of medical polyurethanes was performed. Additionally, information available on the Food and Drug Administration Web site and for corporate Web sites was reviewed in an attempt to identify pertinent information.

RESULTS

The review captured devices that are in testing or have entered clinical practice that use elastomeric polyurethane polymers as disc replacements, dynamic stabilization of spinal movement, or motion limitation to relieve nerve root compression and pain and as complete a listing as possible of such devices that have been designed or tested but appear to no longer be pursued. This review summarizes the available information about the uses to which polyurethanes have been tested or are being used in spinal surgery.

CONCLUSIONS

The use of polyurethanes in medicine has expanded as modifications to the stability of the polymers in the physiological environment have been improved. The potential for the use of elastomeric materials to more closely match the mechanical properties of the structures being replaced and to maintain motion between spinal segments appears to hold promise. The published results from the use of the devices that are discussed show early success with these applications of elastomeric materials.

Study of the polycarbonate-urethane/metal contact in different positions during gait cycle

Nowadays, a growing number of young and more active patients receive hip replacement. More strenuous activities in such patients involve higher friction and wear rates, with friction on the bearing surface being crucial to ensure arthroplasty survival in the long term. Over the last years, the polycarbonate-urethane has offered a feasible alternative to conventional bearings. A finite element model of a healthy hip joint was developed and adjusted to three gait phases (heel strike, mid-stance, and toe-off), serving as a benchmark for the assessment of the results of joint replacement model. Three equivalent models were made with the polycarbonate-urethane Tribofit system implanted, one for each of the three gait phases, after reproducing a virtual surgery over the respective healthy models. Standard body-weight loads were considered: 230% body-weight toe-off, 275% body-weight mid-stance, and 350% body-weight heel strike. Contact pressures were obtained for the different models. When comparing the results corresponding to the healthy model to polycarbonate-urethane joint, contact areas are similar and so contact pressures are within a narrower value range. In conclusion, polycarbonate-urethane characteristics are similar to those of the joint cartilage. So, it is a favorable alternative to traditional bearing surfaces in total hip arthroplasty, especially in young patients.