Deformation of the Durom acetabular component and its impact on tribology in a cadaveric model--a simulator study

Effect of gap outside contact area on lubrication of metal-on-Metal total hip replacement

Ball-in-socket metal on metal (MOM) contacts were analysed using the Abaqus Finite Element package to simulate dry contact between the acetabular cup and the femoral head. Different cup thicknesses of 4, 6, 8, and 10 mm were considered using a polyurethane foam block support system. Elastohydrodynamic lubrication (EHL) analyses were developed for the contacts using three different approaches to specify the contact. These were (i) A simple model based on the radii of relative curvature, (ii) An equivalent contact model developed so that its dry contact area and maximum pressure replicated the values obtained from the FE analysis, and (iii) A modified version of (ii) that also ensured equivalence of the gap shape outside the contact area. Published in vivo information for the hip joint contact forces over the walking cycle was used to specify the operating conditions for the EHL analysis. The analysis method was found to be effective for all points of the walking cycle for cases where the cup thickness exceeded 5 mm and modelling approach (ii) was identified as satisfactory. For a cup thickness of 4 mm, membrane action began to emerge in the FE analyses so that such contacts behaved in a different way.

Titanium Acetabular Component Deformation under Cyclic Loading

Acetabular cup deformation may affect liner/cup congruency, clearance and/or osseointegration. It is unclear, whether deformation of the acetabular components occurs during load and to what extent. To evaluate this, revision multi-hole cups were implanted into six cadaver hemipelvises in two scenarios: without acetabular defect (ND); with a large acetabular defect (LD) that was treated with an augment. In the LD scenario, the cup and augment were attached to the bone and each other with screws. Subsequently, the implanted hemipelvises were loaded under a physiologic partial-weight-bearing modality. The deformation of the acetabular components was determined using a best-fit algorithm. The statistical evaluation involved repeated-measures ANOVA. The mean elastic distension of the ND cup was 292.9 µm (SD 12.2 µm); in the LD scenario, 43.7 µm (SD 11.2 µm); the mean maximal augment distension was 79.6 µm (SD 21.6 µm). A significant difference between the maximal distension of the cups in both scenarios was noted (F(1, 10) = 11.404; p = 0.007). No significant difference was noted between the compression of the ND and LD cups, nor between LD cups and LD augments. The LD cup displayed significantly lower elastic distension than the ND cup, most likely due to increased stiffness from the affixed augment and screw fixation.

Effect of impaction energy on dynamic bone strains, fixation strength, and seating of cementless acetabular cups

Seating a cementless acetabular cup via impaction is a balancing act; good cup fixation must be obtained to ensure adequate bone in-growth and cup apposition, while acetabular fracture must be avoided. Good impaction technique is essential to the success of hip arthroplasty. Yet little guidance exists in the literature to inform surgeons on "how hard" to hit. A drop rig and synthetic bone model were used to vary the energy of impaction strikes in low and high-density synthetic bone, while key parameters such as dynamic strain (quantifying fracture risk), implant fixation, and polar gap were measured. For high energy impaction (15 J) in low-density synthetic bone, a peak tensile strain was observed during impaction that was up to 3.4× as large as post-strike strain, indicating a high fracture risk. Diminishing returns were observed for pushout fixation with increasing energy. Eighty-five percent of the pushout fixation achieved using a 15 J impaction strike was attained by using a 7.5 J strike energy. Similarly, polar gap was only minimally reduced at high impaction energies. Therefore it is suggested that higher energy strikes increase fracture risk, but do not offer large improvements to fixation or implant-bone apposition. It may difficult be for surgeons to accurately deliver specific impaction energies, suggesting there is scope for operative tools to manage implant seating. © 2019 The Authors. Journal of Orthopaedic Research^® published by Wiley Periodicals, Inc. on behalf of Orthopaedic Research Society. J Orthop Res 37:2367-2375, 2019.

Comparing the cup deformation following implantation of a novel ceramic-on-ceramic hip resurfacing bearing to a metal standard in a cadaveric model

Hip resurfacing is an attractive alternative to total hip replacement preserving bone and reducing dislocation risk. Recent metal-on-metal designs have caused failure due to metal wear debris. Ceramic implants may mitigate this risk. Deformation of the acetabular cup can affect the lubrication, producing high friction torques between the femoral head and the cup that would increase wear and/or lead to cup loosening due to femoral head clamping. Our objective was to quantify the deformation of a novel monobloc ceramic hip resurfacing cup component compared to a metal standard, in a fresh frozen cadaveric model using a press-fit technique representative of standard surgical conditions. For this study eight acetabula were prepared from four fresh frozen cadavers. One surgeon with extensive experience in hip resurfacing surgery (J.H.) prepared the acetabulum by sequential reaming. The implants were then impacted into the acetabulum. Four ceramic and four metal implants were used of equal and varying size. Deformation was measured peri-implantation, and at 30 min, using an optical high-precision deformation sensor (GOM GmbH, Braunschweig, Germany). The maximum inscribed circle and the measurement of radial segment techniques were used. Deformation was greater in the metal implants (mean: 34-22mm) immediately after implantation. At 30 min after implantation, the deformation increased to 36mm in the metal and 26mm in the ceramic cup. Greater diameter changes were observed in larger cups. Metal and ceramic implants did not return to the initial diameter. We conclude the ceramic resurfacing acetabular implants undergo similar deformation to existing metal-on-metal implants. The deformation observed was significantly less in the ceramic component at 30 min on one measure. Less deformation may result in better surface conditions and wear characteristics. Deformation change did not resolve after 30 min for both implants.

Early shape change behaviour of an uncemented contemporary hip cup: A cadaveric experiment replicating host bone behaviour through temperature control

Modular uncemented acetabular components are in common use. Fixation is dependent upon press-fit but the forces necessary to achieve initial stability of the construct at implantation may deform the shell and prevent optimal seating of the polyethylene liner insert. Previous work using single-time point measurements in uncontrolled ambient temperature poorly replicates the native state. A controlled study was performed to observe the time-dependent behaviour of an uncemented acetabular shell in the early phase after implantation into the human acetabulum at near physiological temperature. Using a previously validated cadaveric hip model at controlled near physiological temperature with standardised surgical technique, immediate and delayed shell geometry was determined. Eight custom made 3-mm-thick titanium alloy (TiAl6V4) shells were implanted into four cadavers (eight hips). Time-dependent shell deformation was determined using the previously validated ATOS Triple Scan III (ATOS) optical measurement system. The pattern of change in the shape of the surgically implanted shell was measured at three time points after insertion. We found a consistent pattern for quantitative and directional deformation of the shells. In addition, there was consistency for relaxation of the deformation with time. Immediate mean change in shell radius was 104 µm (standard deviation 32, range 67–153) relaxing to mean 96 µm (standard deviation 32, range 63–150) after 10 min and mean 92 µm (standard deviation 28, range 66–138) after 20 min. The clinical significance of this work is the finding of a time-dependent early deformation of acetabular titanium shells on insertion adjusted for near physiological temperature-controlled host bone.

Risk factors for failure of the 36 mm metal-on-metal Pinnacle total hip arthroplasty system: a retrospective single-centre cohort study

Aims

To determine ten-year failure rates following 36 mm metal-on-metal (MoM) Pinnacle total hip arthroplasty (THA), and identify predictors of failure.

Patients and Methods

We retrospectively assessed a single-centre cohort of 569 primary 36 mm MoM Pinnacle THAs (all Corail stems) followed up since 2012 according to Medicines and Healthcare Products Regulation Agency recommendations. All-cause failure rates (all-cause revision, and non-revised cross-sectional imaging failures) were calculated, with predictors for failure identified using multivariable Cox regression.

Results

Failure occurred in 97 hips (17.0%). The ten-year cumulative failure rate was 27.1% (95% confidence interval (CI) 21.6 to 33.7). Primary implantation from 2006 onwards (hazard ratio (HR) 4.30; 95% CI 1.82 to 10.1; p = 0.001) and bilateral MoM hip arthroplasty (HR 1.59; 95% CI 1.03 to 2.46; p = 0.037) predicted failure. The effect of implantation year on failure varied over time. From four years onwards following surgery, hips implanted since 2006 had significantly higher failure rates (eight years 28.3%; 95% CI 23.1 to 34.5) compared with hips implanted before 2006 (eight years 6.3%; 95% CI 2.4 to 15.8) (HR 15.2; 95% CI 2.11 to 110.4; p = 0.007).

Conclusion

We observed that 36 mm MoM Pinnacle THAs have an unacceptably high ten-year failure rate, especially if implanted from 2006 onwards or in bilateral MoM hip patients. Our findings regarding implantation year and failure support recent concerns about the device manufacturing process. We recommend all patients undergoing implantation since 2006 and those with bilateral MoM hips undergo regular investigation, regardless of symptoms.

Cite this article: Bone Joint J 2017;99-B:592–600.

Shell design and reaming technique affect deformation in mobile-bearing total hip arthroplasty acetabular components

Press-fit acetabular components are susceptible to rim deformation. The inherent variability within acetabular reaming techniques may generate increased press-fit and, subsequently, additional component deformation. The purpose of this study was to analyze the insertion and deformation characteristics of acetabular components designed for dual-mobility systems based on component design, size, and reaming technique. Shell deformation was quantified in a validated worst-case scenario foam pinch model. Thin-walled, one-piece, and modular dual-mobility shells of varying size were implanted in under- and over-reamed cavities with insertion force measured and shell deformation assessed using digital image correlation. Increased shell size resulted in larger rim deformation in one-piece components, with a reduction in press-fit by 1 mm resulting in up to 48% reduction in insertion forces and between 23% and 51% reduction in shell deformation. Lower insertion forces and deformations were observed in modular components. Variability in acetabular reaming plays a significant role in the ease of implantation and component deformation in total hip arthroplasty. Modular components are less susceptible to deformation than thin-walled monoblock shells. Care should be taken to avoid excessive under-reaming, particularly in the scenario of large shell size and high-density patient bone stock.

Deformation of the Zurich cementless acetabular cup caused by implantation in a canine cadaver model

OBJECTIVE

To evaluate the change in geometry of the Zurich total hip arthroplasty (THA) acetabular component after implantation.

ANIMALS

Hemipelves from adult mix-breed dogs weighing between 20 and 25 kg.

METHODS

Digital image correlation imaging was performed prior to, immediately after, and 24 hours after impaction of Zurich THA acetabular component, and after removal of the cup from the specimen. Patterns of deformation were qualitatively described, and maximal deformations were compared between time points.

RESULTS

All cups deformed after implantation into the hemipelves by "pinching" in a cranial-caudal direction and dorsoventral expansion, resulting in an ellipsoid configuration to the peripheral rim. The mean ± SD maximum deformation at the rim immediately post-impaction was 0.202 ± 0.052 mm, or approximately 0.4 mm of diametrical deformation. Deformation did not change after the 24-hour saline bath. Impaction and subsequent extraction had a marginal effect on the original cup geometry, as maximum deformation at the rim after cup extraction was 0.074 ± 0.032 mm, relative to prior to impaction.

CONCLUSIONS

The original Zurich cup geometry is distorted as a consequence of the press-fit mechanism. Further studies are required to determine whether deformation induced by impaction has any association with polyethylene wear rates or other prosthesis-related complications.

Retrospective cohort study of the performance of the Pinnacle metal on metal (MoM) total hip replacement: a single-centre investigation in combination with the findings of a national retrieval centre

OBJECTIVES

To determine risk factors for revision in patients implanted with a commonly used metal on metal (MoM) hip replacement.

DESIGN

Retrospective cohort study in combination with a prospective national retrieval study (Northern Retrieval Registry (NRR)).

SETTING

Combined orthopaedic unit in combination with the NRR.

PARTICIPANTS

All patients implanted with a DePuy Pinnacle MoM hip prostheses by the 2 senior authors were invited to attend for a review which included clinical examination, blood metal ion measurements, radiographs and targeted imaging. Explanted components underwent wear analysis using validated methodology and these results were compared with those obtained from the NRR.

RESULTS

489 MoM Pinnacle hips were implanted into 434 patients (243 females and 191 males). Of these, 352 patients attended the MoM recall clinics. 64 patients had died during the study period. For the purposes of survival analysis, non-attendees were assumed to have well-functioning prostheses. The mean follow-up of the cohort as a whole was 89 months. 71 hips were revised. Prosthetic survival for the whole cohort was 83.6% (79.9-87.3) at 9 years. The majority of explanted devices exhibited signs of taper junction failure. Risk factors for revision were bilateral MoM prostheses, smaller Pinnacle liners, and implantation in 2006 and later years. A significant number of devices were found to be manufactured out of their specifications. This was confirmed with analysis of the wider data set from the NRR.

CONCLUSIONS

This device was found to have an unacceptably high revision rate. Bilateral prostheses, those implanted into female patients and devices implanted in later years were found to be at greater risk. A significant number of explanted components were found to be manufactured with bearing diameters outside of the manufacturer's stated tolerances. Our findings highlight the clinical importance of hitherto unrecognised variations in device production.

Acetabular shell deformation as a function of shell stiffness and bone strength

Press-fit acetabular shells used for hip replacement rely upon an interference fit with the bone to provide initial stability. This process may result in deformation of the shell. This study aimed to model shell deformation as a process of shell stiffness and bone strength. A cohort of 32 shells with two different wall thicknesses (3 and 4 mm) and 10 different shell sizes (44- to 62-mm outer diameter) were implanted into eight cadavers. Shell deformation was then measured in the cadavers using a previously validated ATOS Triple Scan III optical system. The shell-bone interface was then considered as a spring system according to Hooke's law and from this the force exerted on the shell by the bone was calculated using a combined stiffness consisting of the measured shell stiffness and a calculated bone stiffness. The median radial stiffness for the 3-mm wall thickness was 4192 N/mm (range, 2920-6257 N/mm), while for the 4-mm wall thickness the median was 9633 N/mm (range, 6875-14,341 N/mm). The median deformation was 48 µm (range, 3-187 µm), while the median force was 256 N (range, 26-916 N). No statistically significant correlation was found between shell stiffness and deformation. Deformation was also found to be not fully symmetric (centres 180° apart), with a median angle discrepancy of 11.5° between the two maximum positive points of deformation. Further work is still required to understand how the bone influences acetabular shell deformation.

The influence of metallic shell deformation on the contact mechanics of a ceramic-on-ceramic total hip arthroplasty

Total hip arthroplasty of ceramic-on-ceramic bearing combinations is increasingly used clinically. The majority of these implants are used with cementless fixation that a metal-backing shell is press-fitted into the pelvic bone. This usually results in the deformation of the metallic shell, which may also influence the ceramic liner deformation and consequently the contact mechanics between the liner and the femoral head under loading. The explicit dynamic finite element method was applied to model the implantation of a cementless ceramic-on-ceramic with a titanium shell and subsequently to investigate the effect of the metallic shell deformation on the contact mechanics. A total of three impacts were found to be necessary to seat the titanium alloy shell into the pelvic bone cavity with a 1 mm diameter interference and a 1.3 kg impactor at 4500 mm s(-1) velocity. The maximum deformation of the metallic shell was found to be 160 µm in the antero-superior and postero-inferior direction and 97 µm in the antero-inferior and postero-superior direction after the press-fit. The corresponding values were slightly reduced to 67 and 45 µm after the ceramic liner was inserted and then modified to 74 and 43 µm under loading, respectively. The maximum deformation and the maximum principal stress of the ceramic liner were 31 µm and 144 MPa (tensile stress), respectively, after it was inserted into the shell and further increased to 52 µm and 245 MPa under loading. This research highlights the importance of the press-fit of the metallic shell on the contact mechanics of the ceramic liner for ceramic-on-ceramic total hip arthroplasties and potential clinical performances.

The influence of the strength of bone on the deformation of acetabular shells: a laboratory experiment in cadavers

Concerns have been raised that deformation of acetabular shells may disrupt the assembly process of modular prostheses. In this study we aimed to examine the effect that the strength of bone has on the amount of deformation of the acetabular shell. The hypothesis was that stronger bone would result in greater deformation. A total of 17 acetabular shells were inserted into the acetabula of eight cadavers, and deformation was measured using an optical measuring system. Cores of bone from the femoral head were taken from each cadaver and compressed using a materials testing machine. The highest peak modulus and yield stress for each cadaver were used to represent the strength of the bone and compared with the values for the deformation and the surgeon's subjective assessment of the hardness of the bone. The mean deformation of the shell was 129 µm (3 to 340). No correlation was found between deformation and either the maximum peak modulus (r² = 0.011, t = 0.426, p = 0.676) or the yield stress (r² = 0.024, t = 0.614, p = 0.549) of the bone. Although no correlation was found between the strength of the bone and deformation, the values for the deformation observed could be sufficient to disrupt the assembly process of modular acetabular components.

Validation of an optical system to measure acetabular shell deformation in cadavers

Deformation of the acetabular shell at the time of surgery can result in poor performance and early failure of the hip replacement. The study aim was to validate an ATOS III Triple Scan optical measurement system against a co-ordinate measuring machine using in vitro testing and to check repeatability under cadaver laboratory conditions. Two sizes of custom-made acetabular shells were deformed using a uniaxial/two-point loading frame and measured at different loads. Roundness measurements were performed using both the ATOS III Triple Scan optical system and a co-ordinate measuring machine and then compared. The repeatability was also tested by measuring shells pre- and post-insertion in a cadaver laboratory multiple times. The in vitro comparison with the co-ordinate measuring machine demonstrated a maximum difference of 5 µm at the rim and 9 µm at the measurement closest to the pole of the shell. Maximum repeatability was below 1 µm for the co-ordinate measuring machine and 3 µm for the ATOS III Triple Scan optical system. Repeatability was comparable between the pre-insertion (below 2 µm) and post-insertion (below 3 µm) measurements in the cadaver laboratory. This study supports the view that the ATOS III Triple Scan optical system fulfils the necessary requirements to accurately measure shell deformation in cadavers.