Far cortical locking can reduce stiffness of locked plating constructs while retaining construct strength

Far cortical locking versus standard locking screw fixation in simulated femoral fractures: A biomechanical meta-analysis

Introduction

Far cortical locking (FCL) is a concept of locking plate fixation with reduced stiffness and symmetric micromotion to improve callus formation. The goal of our study was to review biomechanical data evaluating FCL plate and screw fixation versus standard locking (SL) plate and screw fixation by analyzing studies of cadaveric and synthetic bone models to draw biomechanical conclusions.

Methods

Biomechanical studies that compared FCL and SL plate fixation for simulated femoral fractures were reviewed for construct stiffness, load to failure, axial motion at the near and far cortices, and the difference between near and far cortical axial motion to demonstrate motion symmetry.

Results

FCL decreased stiffness by 1.069 kN/mm compared to SL (95 % CI 0.405 to 1.732, p = 0.002). FCL demonstrated greater axial motion than SL in the near cortex by 0.425 mm (95 % CI 0.359 to 0.491, p < 0.001) and in the far cortex by 0.456 mm (95 % CI 0.378 to 0.534, p < 0.001). FCL resulted in symmetric motion with no significant difference between far and near cortices with the far cortex displacing 0.347 mm more than near (95 % CI -0.038 to 0.731, p = 0.78). SL resulted in asymmetric motion favoring the far cortex by 0.270 mm (0.096-0.443, p = 0.002). Construct strength was not significantly different with FCL load to failure 0.367 kN greater than SL (95 % CI -0.762 to 1.496, p = 0.524).

Conclusion

FCL screw fixation in femoral fractures achieves the goals of reducing construct stiffness and promoting more symmetric axial motion while maintaining construct strength. These results support the overall biomechanical goals of far cortical locking and should encourage investigation into its effects on clinical and radiographic outcomes.

Biomechanical testing of a computationally optimized far cortical locking plate versus traditional implants for distal femur fracture repair

BACKGROUND

This study experimentally validated a computationally optimized screw number and screw distribution far cortical locking distal femur fracture plate and compared the results to traditional implants.

METHODS

24 artificial femurs were osteotomized with a 10 mm fracture gap 60 mm proximal to the intercondylar notch. Three fixation constructs were used. (i) Standard locking plates secured with three far cortical locking screws inserted according to a previously optimized distribution in the femur shaft (n = 8). (ii) Standard locking plates secured with four standard locking screws inserted in alternating plate holes in the femur shaft (n = 8). (iii) Retrograde intramedullary nail secured proximally with one anterior-posterior screw and distally with two oblique screws (n = 8). Axial hip forces (700 and 2800 N) were applied while measuring axial interfragmentary motion, shear interfragmentary motion, and overall stiffness.

FINDINGS

Experimental far cortical locking plate results compared well to published computational findings. Far cortical locking femurs contained the highest axial motion within the potential ideal range of 0.2-1 mm and a sheer-to-axial motion ratio < 1.6 at toe-touch weight-bearing (700 N). At full weight-bearing (2800 N), Standard locking-plated femurs had the only axial motion within 0.2-1 mm but had an excess shear-to-axial motion ratio. Nail-implanted femurs underperformed at both forces.

INTERPRETATION

For toe-touch weight-bearing, the far cortical locking construct provided optimal biomechanics to allow moderate motion, which has been suggested to encourage early callus formation. Conversely, at full weight-bearing, the standard locking construct offered the biomechanical advantage on fracture motion.

The use of customized 3D-printed mandibular prostheses with pressure-reducing device: A clinical trial

BACKGROUND

Segmental bone defects of the mandible result in the complete loss of the affected region. We had incorporated the pressure-reducing device (PRD) designs into the customized mandible prostheses (CMP) and conducted a clinical trial to evaluate this approach.

METHODS

Seven patients were enrolled in this study. We examined the association among the history of radiotherapy, the number of CMP regions, the number of chin regions involved, and CMP exposure.

RESULTS

We included five men and two women with an average age of 55 years. We excised tumors with an average weight of 147.8 g and the average weight of the CMP was 68.5 g. No significant difference between the two weights was noted (p = 0.3882). Three patients received temporary dentures and the CMP remained stable in all patients.

CONCLUSION

The use of PRD in CMP may address the previous challenges associated with CMP, but further research is necessary.

Biomechanical effects of muscle loading on early healing of femoral stem fractures: a combined musculoskeletal dynamics and finite element approach

Femoral stem fractures (FST) are often accompanied by muscle injuries, however, what muscle injuries affect fracture healing and to what extent is unknown. The purpose of this study was to analyze the extent to which different muscles affect FST healing through a combined musculoskeletal dynamics and finite element approach. Modeling the lower extremity musculoskeletal system for 12 different muscle comprehensives. Muscle and joint reaction forces on the femur were calculated and these data were used as boundary conditions input to the FSTs model to predict the degree of muscle influence on fracture healing. Finally, we will investigate the extent to which muscle influences FST healing during knee flexion. Muscle and joint forces are highly dependent on joint motion and have a significant biomechanical influence on interfragmentary strain (IFS) healing. The psoas major (PM), gastrocnemius lateralis (GL) and gastrocnemius medialis (GM) muscles play a major role in standing, with GM > PM > GL, whereas the gluteus medius posterior (GMP), vastus intermedius (VI), vastus medialis (VM), vastus lateralis superior (VLS), and adductor magnus distalis (AMD) muscles play a major role in knee flexion, with VLS > VM > VI > AMD > GMP. Mechanical stimulus-controlled healing can be facilitated when the knee joint is flexed less than 20°. Different muscles exert varying degrees of influence on the healing of fractures. Therefore, comprehending the impact of particular muscles on fracture site tissue FST healing can aid orthopedic surgeons in formulating improved surgical and rehabilitation strategies.

Promoting bone callus formation by taking advantage of the time-dependent fracture gap strain modulation

Delayed union and non-union of fractures continue to be a major problem in trauma and orthopedic surgery. These cases are challenging for the surgeon. In addition, these patients suffer from multiple surgeries, pain and disability. Furthermore, these cases are a major burden on healthcare systems. The scientific community widely agrees that the stability of fixation plays a crucial role in determining the outcome of osteosynthesis. The extent of stabilization affects factors like fracture gap strain and fluid flow, which, in turn, influence the regenerative processes positively or negatively. Nonetheless, a growing body of literature suggests that during the fracture healing process, there exists a critical time frame where intervention can stimulate the bone's return to its original form and function. This article provides a summary of existing evidence in the literature regarding the impact of different levels of fixation stability on the strain experienced by newly forming tissues. We will also discuss the timing and nature of this "window of opportunity" and explore how current knowledge is driving the development of new technologies with design enhancements rooted in mechanobiological principles.

Finite element modeling of fracture compression by compression plates

Dynamic compression plating is a common type of fracture fixation used to compress between bone fragments. The quality of compression across the fracture is important for postoperative stability and primary bone healing. Compression quality may be affected by surgical variations in plate prebend, screw location, screw torque, fracture gap, and implant material. Computational modeling provides a tool for systematically examining these factors, and for visualizing the mechanisms involved. The purpose of this study was to develop a finite element model of dynamic compression plating that includes screw insertion under torque control, establish model credibility through sensitivity analyses and experimental validation, and use the model to examine the effects of surgical variables on fracture compression and postoperative stability. Model-predicted compressive pressures had good agreement with corresponding synthetic bones experiments under a variety of conditions. Models demonstrated that introducing a 1.5 or 3 mm plate prebend (using a 4.5 mm narrow LCP plate) eliminated gapping at the far cortex, which is consistent with clinical recommendations. However, models also revealed that plate prebend led to sharp decreases in fracture compressive force, exceeding 80% in some cases. A 1.5 mm plate prebend resulted in the most uniform pressures across the fracture. Testing of a simplified model form used in previous computational modeling studies showed large inaccuracies for constructs with plate prebend. This study provides the first experimentally validated computational models of dynamic compression plate fracture fixation, and reveals important effects of plate prebend and fracture gap on fracture compression quality.

Are TomoFix Locking Plates Really Anatomical for Indian Population?

Purpose

The use of a TomoFix plate can be a challenge in Asian population who inherently have smaller tibial bones. This study aims to find out the normal proximal tibial morphometric measurements in Indian population and to compare the Medial Anterior Radius of Curvature (MAROC) of proximal tibia with the Proximal Part Radius of Curvature (PPROC) of the available TomoFix plates, to estimate conformity of the fit between them.

Methods

Retrospective Computed Tomography (CT) and Magnetic Resonance Imaging (MRI) based proximal tibial measurements were performed on 824 knees, 664 females and 160 males (604 patients). The mean MAROC, mean MAROC in males and mean MAROC in females were compared to the PPROC of TomoFix plates.

Results

The radiological measurements revealed a mean AP length of 45.22 ± 3.79 mm, mean ML width of 69.04 ± 5.01 mm and mean MAROC of 21.88 ± 2.11 mm. The mean MAROC in males was 24.07 ± 2.1 mm, whereas in females it was 21.35 ± 1.75 mm. The mean MAROC, mean MAROC in males and mean MAROC in females when compared to the PPROC of Standard TomoFix plate (38 mm), Small TomoFix and Anatomical TomoFix plates (30 mm) showed a significant difference (p < 0.01), indicating that the radius of curvature of the plate does not match the radius of curvature of the anteromedial tibial plateau.

Conclusion

The TomoFix plates, including Small (Asian Version) and Anatomical plates, are relatively large for the Indian population. Our study may help the implant to designers develop a plate that will better suit the Indian population, improving results and reducing hardware-related complications of MOWHTO.

Far cortical locking constructs for fixation of distal femur fractures in an Asian population: A prospective observational study

BACKGROUND

The stiffness of locked plates suppresses healing process, prompting the introduction of far cortical locking to address this issue. This study aimed to demonstrate the clinical efficacy of far cortical locking constructs in treating distal femoral fractures in an Asian population.

METHODS

This multicenter prospective observational study was conducted at four university hospitals between February 2018 and February 2021. Demographic data, the presence of metaphyseal comminution, and surgical fixation details were recorded. Clinical outcomes, including single-leg standing, EQ-5D, and EQ-VAS scores, and radiologic outcomes, including the RUST score of each cortex, were evaluated and compared according to the presence of metaphyseal comminution.

RESULTS

There were 37 patients (14 men and 23 women) with a mean age of 67.3 ± 11.8 years. Twenty-two patients had metaphyseal comminution (59%), and 15 presented simple fractures in metaphyseal areas. Four patients (13%) could stand on one leg >10s at 6 weeks, and 24 patients (92%) at 1 year. EQ-5D increased from 0.022 ± 0.388 to 0.692 ± 0.347, and the mean EQ-VAS 51.1 ± 13.1 to 74.1 ± 24.1 between discharge (n = 37) and post-operative 1 year (n = 33), respectively. RUST score presented increment for time, from 6.2 ± 1.8 at 6 week to 11.6 ± 1.1 at 1 year. Radiological healing demonstrated rapid increase from week 6 (16/28, 43%) to month 3 (27/31, 87%), with no obvious increase was observed in 6 months (23/26, 89%) or 12 months (25/28, 89%). Simple metaphyseal fractures presented significantly higher RUST scores at 6 weeks and 3 months, but there was no difference in RUST scores at 6 months or 1 year according to metaphyseal comminution.

CONCLUSIONS

Plate constructs with far cortical locking screws provided safe and effective fixation for distal femoral fractures, with consistent radiological and clinical results, regardless of metaphyseal comminution.

Biomechanics of fracture healing: how best to optimize your construct in the OR

Orthopaedic surgeons routinely assess the biomechanical environment of a fracture to create a fixation construct that provides the appropriate amount of stability in efforts to optimize fracture healing. Emerging concepts and technologies including reverse dynamization, "smart plates" that measure construct strain, and FractSim software that models fracture strain represent recent developments in optimizing construct biomechanics to accelerate bone healing and minimize construct failure.

Does Far Cortical Locking Improve Fracture Healing in Distal Femur Fractures: A Randomised, Controlled, Prospective Multicentre Study

(1) Background: Bone healing is influenced by various mechanical factors, such as stability, interfragmentary motion, strain rate, and direction of loading. Far cortical locking (FCL) is a novel screw design that promotes bone healing through controlled fracture motion. (2) Methods: This study compared the outcome of distal femur fractures treated with FCL or SL (standard locking) screws and an NCB plate in a randomised controlled prospective multicentre trial. The radiographic union scale (RUST) and healing time was used to quantify bone healing on follow-up imaging. (3) Results: The study included 21 patients with distal femur fractures, 7 treated with SL and 14 treated with FCL screws. The mean working length for patients with SL screws was 6.1, whereas for FCL screws, it was 3.9. The mean RUST score at 6 months post fracture was 8.0 for patients with SL plates and 7.3 for patients with FCL plates (p value > 0.05). The mean healing time was 6.5 months for patients with SL plates and 9.9 months for patients with FCL plates (p value < 0.05). (4) Conclusions: Fractures fixed with SL plates had longer working lengths and faster healing times when compared to FCL constructs, suggesting that an adequate working length is important for fracture healing regardless of screw choice.

Effect of knee osteoarthritis on the postoperative outcome of proximal femoral nail anti-rotation in the treatment of intertrochanteric fractures in the elderly: a retrospective analysis

BACKGROUND

The proximal femoral nail anti-rotation (PFNA) is a commonly used internal fixation system for intertrochanteric fractures (IFs) in older adults. Knee osteoarthritis (KOA) is a degenerative lower extremity disease that occurs most frequently in the elderly. Some patients have already had KOA before the IFs. However, whether KOA impacts the postoperative outcome of IFs has not been reported.

OBJECTIVE

This study aimed to investigate the effect of KOA on the fracture side on the outcome after PFNA for IFs in the elderly.

METHODS

Between January 2016 and November 2021, 297 elderly patients treated with PFNA for IFs were enrolled in this study. They were divided into two groups according to the American Rheumatism Association KOA clinical and radiographic criteria: the control group and the KOA group. Intraoperative bleeding, operative time, length of hospital stay, postoperative time out of bed, fracture healing time, postoperative complications, postoperative Harris hip function score, and Barthel ability to daily living Score were compared between the two groups. Follow-up was routinely scheduled at 1, 3, 6, and 12 months postoperatively.

RESULTS

Based on the exclusion criteria, 254 patients who met the requirements were left to be included in this study, including the control group (n = 133) and the KOA group (n = 121). Patients were followed up for a mean of 17.5 months (12-24 months). There was no significant difference between the two groups in preoperative demographic data, intraoperative blood loss, operation time, and length of stay in the hospital. The control group was statistically significant compared to the KOA group in terms of postoperative time out of bed (17.8 ± 4.0 days vs. 19.1 ± 5.8 days), fracture healing time (13.7 ± 2.2 weeks vs. 14.6 ± 3.7 weeks), and postoperative complications (12.8 vs. 23.1%). The Harris hip function score and Barthel ability to daily living score were higher in the control group than in the KOA group at 1, 3, 6, and 12 months postoperatively (the control group: 63.8 ± 10.9, 71.8 ± 10.3, 81.5 ± 8.7, and 91.6 ± 6.3 vs. The KOA group 61.0 ± 10.4, 68.6 ± 9.1, 79.0 ± 9.2, and 88.5 ± 5.9).

CONCLUSIONS

In elderly patients with IFs combined with KOA of the fracture side treated with PFNA internal fixation, KOA increases the incidence of postoperative complications of the fracture, prolongs postoperative time out of bed and fracture healing, and reduces postoperative hip function and ability to daily living. Therefore, treating KOA on the fractured side needs to be considered when treating IFs in the elderly.

Risk Factors of Proximal Screw Breakage of Locking Plate (ZPLP®) after MIPO for Distal Femur Fractures -Analysis of Patients with Plate Removal after Bony Union

BACKGROUND

Locking a compression plate is a more favorable surgical technique than intramedullary nailing in the treatment of distal femur fractures. This study analyzed the risk factors of proximal screw breakage retrospectively, which was confirmed in the patients with plate removal after bony union.

METHODS

A total of 140 patients who were fixed by MIPO using ZPLP from 2009 to 2019 were identified. A total of 42 patients met the inclusion criteria and were included. The screw breakage group (12 patients) and the non-breakage group (30 patients) were compared.

RESULTS

Approximately 12 (28.6%) of 42 plate-removal patients showed proximal screw breakage. The breakage of proximal screws developed at the junction of the screw head and neck. The number of broken proximal screws averaged 1.4 (1~4). The breakage of the proximal screw even after the bony union is more frequent in older patients (p = 0.023), the dominant side (p = 0.025), the use of the cortical screw as the proximal uppermost screw (p = 0.039), and the higher plate-screw density (p = 0.048).

CONCLUSIONS

Advanced age, dominant side, use of the cortical screw as the uppermost screw, and higher plate-screw density were related to proximal screw breakage. When the plate is removed after bony union or delayed union is shown in these situations, the possibility of proximal screw breakage should be kept in mind.

The Use of Optical Tracking to Characterize Fracture Gap Motions and Estimate Healing Potential in Comminuted Biomechanical Models of Surgical Repair

Fracture healing is stimulated by micromotion at the fracture site, whereby there exists an optimal amount of strain to promote secondary bone formation. Surgical plates used for fracture fixation are often evaluated for their biomechanical performance using benchtop studies, where success is based on overall construct stiffness and strength measures. Integration of fracture gap tracking to this assessment would provide crucial information about how plates support the various fragments present in comminuted fractures, to ensure there are appropriate levels of micromotion during early healing. The goal of this study was to configure an optical tracking system to quantify 3D interfragmentary motion to assess the stability (and corresponding healing potential) of comminuted fractures. An optical tracking system (OptiTrack, Natural Point Inc, Corvallis, OR) was mounted to a material testing machine (Instron 1567, Norwood, MA, USA), with an overall marker tracking accuracy of 0.05 mm. Marker clusters were constructed that could be affixed to individual bone fragments, and segment-fixed coordinate systems were developed. The interfragmentary motion was calculated by tracking the segments while under load and was resolved into compression-extraction and shear components. This technique was evaluated using two cadaveric distal tibia-fibula complexes with simulated intra-articular pilon fractures. Normal and shear strains were tracked during cyclic loading (for stiffness tests), and a wedge gap was also tracked to assess failure in an alternate clinically relevant mode. This technique will augment the utility of benchtop fracture studies by moving beyond total construct response and providing anatomically relevant data on interfragmentary motion, a valuable proxy for healing potential.

Fixators dynamization for delayed union and non-union of femur and tibial fractures: a review of techniques, timing and influence factors

The optimal balance between mechanical environment and biological factors is crucial for successful bone healing, as they synergistically affect bone development. Any imbalance between these factors can lead to impaired bone healing, resulting in delayed union or non-union. To address this bone healing disorder, clinicians have adopted a technique known as "dynamization" which involves modifying the stiffness properties of the fixator. This technique facilitates the establishment of a favorable mechanical and biological environment by changing a rigid fixator to a more flexible one that promotes bone healing. However, the dynamization of fixators is selective for certain types of non-union and can result in complications or failure to heal if applied to inappropriate non-unions. This review aims to summarize the indications for dynamization, as well as introduce a novel dynamic locking plate and various techniques for dynamization of fixators (intramedullary nails, steel plates, external fixators) in femur and tibial fractures. Additionally, Factors associated with the effectiveness of dynamization are explored in response to the variation in dynamization success rates seen in clinical studies.

Treatment of comminuted metaphyseal distal femoral fractures with a micromotion-balancing osteosynthesis: an animal study

BACKGROUND

Locking plates are commonly used in the treatment of comminuted metaphyseal distal femoral fractures. However, locking plates form a strong structure and promote asymmetrical callus formation, which is not conducive for rapid fracture healing and may increase fracture risk. To overcome this, we designed a micromotion-balancing fixation system based on locking plates.

METHODS

Six healthy pigs (Bama miniature pigs) were used to establish a model of bilateral comminuted distal femoral fracture (AO/ASIF: 33-C2). Standard drilling was performed on one of each pig's hind limbs (control group), whereas eccentric drilling was performed on the other hind limb (experimental group). Both femurs were fixed with a 3-hole locking compression plate using 5-mm-diameter screws. At 12 postoperative weeks, all pigs were euthanized and the femurs with compression plates were radiographically examined. The level of fracture healing and loosening/internal fixation failure were recorded. Bone mineral density, number of trabeculae, trabecular morphology, and calcification precipitations were assessed.

RESULTS

All pigs survived, and the fractures healed. No complications related to fracture healing, such as infection and internal fixation failure, were noted. The bone mineral density of the near and far cortical calli, number of the near and far cortical callus trabeculae, and difference in bone mineral density between the near and far cortical calli in the experimental group were significantly higher than those in the control group (p < 0.01). However, the difference in the number of trabeculae between the near and far cortical calli was significantly lower in the experimental group than in the control group (p < 0.01).

CONCLUSION

This newly designed system provides stable fixation for comminuted distal femoral fracture, increases the overall strain at the fracture site, and balances the strains at the near and far cortices to achieve uniform callus growth and fracture healing.

Is there a Difference in Interfragmentary Compression Strength Between Fully or Partially Threaded Screws? Results of an Experimental Biomechanical Pilot Study

Objective  This study assessed differences between fully- and partially-threaded screws in the initial interfragmentary compression strength. Our hypothesis was that there would be an increased loss in initial compression strength with the partially-threaded screw. Methods  A 45-degree oblique fracture line was created in artificial bone samples. The first group (FULL, n  = 6) was fixed using a 3.5-mm fully-threaded lag screw, while the second group (PARTIAL, n  = 6) used a 3.5-mm partially-threaded lag screw. Torsional stiffness for both rotational directions were evaluated. The groups were compared based on biomechanical parameters: angle-moment-stiffness, time-moment-stiffness, maximal torsional moment (failure load), and calibrated compression force based on pressure sensor measurement. Results  After loss of one PARTIAL sample, no statistically significant differences in calibrated compression force measurement were observed between both groups: [median (interquartile range)] FULL: 112.6 (10.5) N versus PARTIAL: 106.9 (7.1) N, Mann-Whitney U-test: p  = 0.8). In addition, after exclusion of 3 samples for mechanical testing (FULL n  = 5, PARTIAL n  = 4), no statistically significant differences were observed between FULL and PARTIAL constructs in angle-moment-stiffness, time-moment-stiffness, nor maximum torsional moment (failure load). Conclusion  There is no apparent difference in the initial compression strength (compression force or construct stiffness or failure load) achieved using either fully- or partially-threaded screws in this biomechanical model in high-density artificial bone. Fully-threaded screws could, therefore, be more useful in diaphyseal fracture treatment. Further research on the impact in softer osteoporotic, or metaphyseal bone models, and to evaluate the clinical significance is required.

Geometrical analysis of the opening gap after tibial condylar valgus osteotomy for proper hinge point selection

Background

Preoperative deformity and hinge position are associated with the magnitude of the gap opening during corrective osteotomy. A larger opening gap angle is associated with a higher risk of complications. This cross-sectional study sought to identify a suitable hinge position that results in the smallest opening angle during tibial condylar valgus osteotomy (TCVO).

Methods

The data of 66 arthritic knees treated by TCVO were included, comprising 16 knees with the hinge points selected medial to the center (group M), 21 knees with the hinge points selected at the center (group C), and 29 knees with the hinge points selected lateral to the center of the intercondylar eminence (group L). The opening gap angles and the correction amounts of the medial proximal tibial angle (ΔMPTA) were compared among the 3 groups to identify the preliminary relationship between the hinge positions and the opening gap angle. A simplified geometric model with the hinge positions selected at the medial beak, the center, and the lateral beak of the intercondylar eminence was constructed to simulate the realignment process. Several anatomical points were allocated as Cartesian coordinates. The opening gap angle with different hinge positions was mathematically formulated with MATLAB (MathWorks, Natick, MA, USA).

Results

The average ΔMPTAs were 9.4±2.9°, 9.4±3.5°, and 9.3±3.0° in groups L, C, and M, respectively. The opening angle of the osteotomy gap was the largest in group M and the smallest in group L (29.7±11.1° and 16.9±5.3°; P<0.01). The comparison of the opening angle per the ΔMPTA revealed a similar pattern. The simulated realignment process indicated that the hinge point at the lateral beak of the intercondylar eminence led to the smallest opening angle. The opening angle during TCVO was mathematically derived in terms of the ΔMPTA, the position of the intersection of the pre- and postoperative joint lines, and the position of the hinge point.

Conclusions

The hinge point at the lateral beak of the intercondylar eminence results in the smallest opening angle and may be suitable for TCVO.

Micromotion-based balanced drilling technology to increase near cortical strain

Objective

A micromotion-based balanced drilling system was designed based on a locking plate (LP) and far cortical locking (FCL) concept to maintain the balance of micromotions of the cortex on both sides of a fracture region. The system was tested by axial compression test.

Methods

The fracture gap was set to 2 cm, and locking screws with a diameter of 5 mm and a locking plate were used to fix it. The diameters of the two sections of the stepping drill were 3.5 mm and 5.0 mm, respectively. One of the matching drilling sleeves was a standard sleeve (eccentricity, 0 mm) and the other was an eccentric sleeve (proximal eccentricity, 1 mm). A model of the fixed locking plate (AO/ASIF 33-A3) for distal femoral fractures with a gap of 2 cm was established based on data from 42 artificial femurs (SAWBONE). According to the shape of the screw holes on the cortex, the fixed fracture models were divided into a control group (standard screw hole group X126, six cases) and an experimental group (elliptical screw hole group N, 36 cases). The experimental group was further divided into six subgroups with six cases in each (N126, N136, N1256, N1356, N12356, N123456), based on the number and distribution of the screws on the proximal fracture segment. The control, N126, and N136 groups were subjected to an axial load of 500 N, and the other groups were subjected to an axial load of 1000 N. The displacements of the kinetic head, far cortex, and near cortex were measured. The integral structural stiffness of the model and the near cortical strain were calculated. The data of each group were analyzed by using a paired t-test.

Results

When the far cortical strains were 2%, 5%, and 10%, the near cortical strains in group N126 were 0.96%, 2.35%, and 4.62%, respectively, significantly higher than those in the control group (X126) (p < 0.05). For a different distribution of the screws, when the far cortical strains were 2%, 5%, and 10%, the near cortical strains in group N126 were significantly higher than those in group N136 (p < 0.05). However, there was no significant difference between the near cortical strains in the two groups with four screws (p > 0.05). For different numbers of screws, the near cortical strains in the three-screw groups were significantly higher than those in the four-screw groups (p < 0.05), and there was no significant difference in near cortical strains among the four-, five-, and six-screw groups (p > 0.05).

Conclusion

The proposed drill and matching sleeves enabled a conventional locking compression plate to be transformed into an internal fixation system to improve the balanced motion of the near and far cortices. Thus, strain on a fracture site could be controlled by adjusting the diameter of the drill and the eccentricity of the sleeve.

Efficacy of Far Cortical Locking Screws in Treating Distal Tibia Fractures in Comparison With That of Standard Locking Screws

There are no clinical studies about treatment of distal tibia fractures using far cortical locking (FCL) screws, even though it has been shown to be superior to standard locking screws in biomechanical studies. We compared the efficacy of FCL screws to that of traditional locking screws. Twenty-five distal tibia fractures were treated with minimally invasive plate osteosynthesis using traditional locking screws, whereas 20 were treated using FCL screws. We retrospectively compared time taken for callus formation and radiographic bone union between 2 groups. The effect of age, sex, diabetes, and smoking history on bone healing was analyzed. Complications were also noted. As a result, there was no significant difference in age (p = .292), sex (p = 1.0), diabetes (p = 1.0), or smoking history (p = .704) between 2 groups. Time to callus formation was 77.5 days in the FCL group, and 96 days in the traditional group (p = .023). Average time to bone union was 134.8 days, and 163.1 days in the FCL group and the traditional group, respectively (p = .017). There was one case of screw loosening in the FCL group, and one case of screw breakage in the traditional group. This study suggests that FCL screws promote quicker healing of distal tibia fractures than traditional locking screws.

Optimal design and biomechanical analysis of sandwich composite metal locking screws for far cortical locking constructs

In the interests of more flexible and less stiff bridge constructs to stimulate bone healing, the technique of far cortical locking has been designed to improve locked plating constructs in terms of stress concentration, stress shielding, and inhibition of issues around fracture healing. However, far cortical locking screws currently lack objective designs and anti-fatigue designs. This study investigates an optimization algorithm to form a special locking screw composed of various metals, which can theoretically achieve the maintenance of the excellent mechanical properties of far cortical locking constructs in terms of fracture internal fixation, while maintaining the biomechanical safety and fatigue resistance of the structure. The numerical results of our study indicate that the maximum von Mises stress of the optimized construct is less than the allowable stress of the material under each working condition while still achieving sufficient parallel interfragmentary motion. Numerical analysis of high cycle fatigue indicates that the optimized construct increases the safety factor to five. A high cycle fatigue test and defect analysis indicates that the sandwich locking constructs have better fatigue resistance. We conclude that the sandwich locking construct theoretically maintains its biomechanical safety and fatigue resistance while also maintaining excellent mechanical properties for fracture internal fixation.

Is a Complete Anatomical Fit of the Tomofix Plate Biomechanically Favorable? A Parametric Study Using the Finite Element Method

BACKGROUND

The opening wedge high tibial osteotomy (HTO) fixation using the Tomofix system is at the risk of mechanical failure due to unstable fixation, lateral hinge fracture, and hardware breakage. This study aimed to investigate the effect of the level of anatomical fit (LOF) of the plate on the failure mechanisms of fixation.

METHODS

A finite element model of the HTO with a correction angle of 12 degrees was developed. The LOF of the TomoFix plate was changed parametrically by altering the curvature of the plate in the sagittal plane. The effect of the LOF on the fixation performance was studied in terms of the factor of safety (FOS) against failure mechanisms. The FOSs were found by 1) dividing the actual stiffness of the plate-bone construct by the minimum allowable one for unstable fixation, 2) dividing the compressive strength of the cortical bone by the actual maximum pressure at the lateral hinge for the lateral hinge fracture, and 3) the Soderberg criterion for fatigue fracture of the plate and screws.

RESULTS

The increase of the LOF by applying a larger bent to the plate changed the fixation stiffness slightly. However, it reduced the lateral hinge pressure substantially (from 182 MPa to 71 MPa) and increased the maximum equivalent stresses in screws considerably (from 187 MPa to 258 MPa). Based on the FOS-LOF diagram, a gap smaller than 2.3 mm was safe, with the highest biomechanical performance associated with a 0.5 mm gap size.

CONCLUSION

Although a high LOF is necessary for the Tomofix plate fixation to avoid mechanical failure, a gap size of 0.5mm is favored biomechanically over complete anatomical fit.

Influence of the Near-Cortical Over-Drilling Technique on the Mechanical Behaviour of Locking Plate Constructs Applied in Maned Wolf's Femur

OBJECTIVE

 The aim of this study was to evaluate the influence of near-cortical over-drilling holes on the mechanical behaviour of locking plate constructs applied in maned wolf's femur by using mechanical testing and finite element method (FEM).

STUDY DESIGN

 Seven pairs of adult maned wolves (Chrysocyon brachyurus) femur bones were randomly distributed into four groups. In all groups, a 3.5 mm locking compression plate, designed with 12 combi-holes and one locked, was applied to the lateral surface of the femur. G1 (n = 4) received bicortical locking screws placed in holes 1, 3, 5, 8, 10 and 12. In G2 (n = 5), the plate was applied as used in G1, but the application of the locked screws involved the near-cortical over-drilling technique. In G3 (n = 4), the plate was applied as used in G2, but the size of the near-cortical over-drilling was larger. The combi-holes 6 and 7 were maintained over a 10 mm fracture gap without screws. All constructs were tested for failure in the axial load. The axial load was applied eccentrically to the femoral head.

RESULTS

 Statistical differences were observed in the maximum load with G3 > G1 and G3 > G2, and in the deflection with G2 > G1 and G2 > G3. The FEM showed the lowest total displacement of the bone-plate constructs as well as of the plate in G1 compared with G2 and G3.

CONCLUSION

 The near-cortical over-drilling technique used in unstable fractures induced in the maned wolf's femur showed by static axial compression test that maximum load and deflection are dependent on drill hole size induced in the near-cortex. Based on FEM, the lowest total displacement of the bone-plate constructs was observed in Group 1.

The Use of Customized Three-Dimensionally Printed Mandible Prostheses with a Pressure-Reducing Device: A Finite Element Analysis in Different Chewing Positions, Biomechanical Testing, and In Vivo Animal Study Using Lanyu Pigs

Segmental bony defects of the mandible constitute a complete loss of the regional part of the mandible. Although several types of customized three-dimension-printed mandible prostheses (CMPs) have been developed, this technique has yet to be widely used. We used CMP with a pressure-reducing device (PRD) to investigate its clinical applicability. First, we used the finite element analysis (FEA). We designed four models of CMP (P1 to P4), and the result showed that CMP with posterior PRD deployment (P4 group) had the maximum total deformation in the protrusion and right excursion positions, and in clenching and left excursion positions, posterior screws had the minimum von Mises stress. Second, the P4 CMP-PRD was produced using LaserCUSING from titanium alloy (Ti-6Al-4V). The fracture test result revealed that the maximum static pressure that could be withstood was 189 N, and a fatigue test was conducted for 5,000,000 cycles. Third, animal study was conducted on five male 4-month-old Lanyu pigs. Four animals completed the experiment. Two animals had CMP exposure in the oral cavity, but there was no significant inflammation, and one animal had a rear wing fracture. According to a CT scan, the lingual cortex of the mandible crawled along the CMP surface, and a bony front-to-back connection was noted in one animal. A histological examination indicated that CMP was significantly less reactive than control materials (p = 0.0170). Adequate PRD deployment in CMP may solve a challenge associated with CMP, thus promoting its use in clinical practice.

Biomechanical Comparison of Use of Two Screws versus Three Screws Per Fragment with Locking Plate Constructs under Cyclic Loading in Compression in a Fracture Gap Model

OBJECTIVES

 The aim of this study was to measure and compare the stiffness and cyclic fatigue of two plate-bone model constructs, with either two or three locking screws per fragment, under cyclic compression.

METHODS

 A 10-hole 3.5 mm stainless steel locking compression plate (LCP) was fixed 1 mm from a synthetic bone model in which the fracture gap was 47 mm. Two groups of 10 constructs, prepared with either two or three bicortical locking screws placed at the extremities of each fragment, were tested in a load-controlled compression test until failure.

RESULTS

 The three-screw constructs were stiffer than the two-screw constructs (196.75 ± 50.48 N/mm and 102.43 ± 22.93 N/mm, respectively) and the actuator displacements of the two-screw constructs were higher (18.02 ± 1.07 mm) than those of the three-screw constructs (14.48 ± 2.25 mm). The number of cycles to failure of the two-screw constructs was significantly lower (38,337.50 ± 2,196.98) than the that of the three-screw constructs (44,224.00 ± 1,515.24). Load at irreversible deformation was significantly lower in the two-screw constructs (140.93 ± 13.39 N) than in the three-screw constructs (184.27 ± 13.17 N). All constructs failed by plate bending at the gap between the two cylinders.

CLINICAL SIGNIFICANCE

 Omission of the third innermost locking screw during bridging osteosynthesis subjected to compression forces led to a 13.3% reduction in the number of cycles to failure and a 23.5% reduction of the load withstood by the plate before plastic deformation occurred.

Effects of plate contouring quality on the biomechanical performance of high tibial osteotomy fixation: A parametric finite element study

Locking plates have threaded holes, in which threaded-head screws are affixed. Hence, they do not need to be in intimate contact with underlying bone to provide fixation. There are, however, reports that a large distance between the plate and the bone might cause clinical complications such as delayed union or nonunion, screw pull out, and screw and plate breakage. Considering the diversity in the capabilities and costs of different plate customization techniques, the purpose of this study was to investigate the effect of the plate contouring quality on the biomechanical performance of high tibial osteotomy (HTO) fixation. A finite element model of proximal tibia was developed in Abaqus, using the QCT data of a cadaver. The model was then subjected to open-wedge HTO (correction angle 12°) with TomoFix plate fixation. The sagittal curvature of the plate was changed parametrically to provide certain levels of geometrical fit, and the biomechanical performance parameters of fixation were assessed. Results indicated 5%, 9% and 38% increase in the stiffness of the construct, and the von Mises stress in the plate and locking screw just above the osteotomy site, respectively, when the level of fit of plate changed from 0% (initial non-contoured initial shape) to 100% (fully adapted shape). The same change decreased the pressure at the lateral hinge of the osteotomy by 61%, and the mean of the tensile stress on the screw shaft by 12%. It was concluded that the level of fit has conflicting effects on the biomechanical parameters of the HTO fixation system, that is, the structural stiffness, the pressure at the lateral hinge, the stresses in the plate and screws, and the pull out resistance of the screws. In particular, for HTO patients with high quality bone, the optimal level of fit should provide a tradeoff between these parameters.

Is retrograde nailing superior to lateral locked plating for complete articular distal femur fractures?

INTRODUCTION

Nonunion rates for distal femur fractures treated with lateral locked plating (LLP) remains as high as 18-22% despite significant advances with implant design and construct modulation. However, whether treatment of distal femur fractures with rIMN has improved outcomes compared to LLP has not been well characterized. The purpose of this study was to compare outcomes of complete articular distal femur fractures (AO/OTA 33-C) treated with either LLP or rIMN.

METHODS

106 distal femur fractures in 106 patients between January 2014 and January 2018 were identified. Medical records were reviewed to collect patient age, gender, body mass index, sagittal and coronal plane alignment on immediate postoperative radiographs, time to union, incidence of nonunion, and incidence of secondary operative procedures for repair of a nonunion.

RESULTS

Of 106 patients, 50 underwent rIMN and 56 underwent LLP. The mean age at the time of injury was 51 years (21 to 86 years) and there were 55 males. Average coronal alignment of 83.7° of anatomic lateral distal femoral angle (aLDFA) and sagittal alignment of <1° of apex anterior angulation in the rIMN group. In the LLP group there was an average of 87.9° of aLDFA and 1.9° of apex anterior angulation (p = .005 and p = .36). Average time to union in the rIMN group was 6 months and 6.6 months in the LLP group (p = .52). Incidence of nonunion in the rIMN group was 11.8% and 27.5% in the LLP group (p = .008). There were 8 secondary procedures for nonunion in the rIMN group and 18 in the LLP group (p = .43).

CONCLUSIONS

Our results demonstrated a higher nonunion rate and coronal plane malalignment with LLP compared to rIMN. While prospective data is required, rIMN does appear to be an appropriate treatment for complete articular distal femur fractures with a potentially decreased rate of nonunion .

Modeling attachment and compressive loading of locking and non-locking plate fixation: a finite element investigation of a supracondylar femur fracture model

This study developed a finite element (FE) model of simulated locking plate fixation to examine the strain response following supracondylar femoral plate attachment and under compressive loading. An implicit FE model of a synthetic femur with a distal fracture gap stabilized with a lateral plate was evaluated following attachment and 500 N loading, considering locking and non-locking proximal screws configurations. Screw pre-tension values of 60 N for both distal and proximal non-locking screws yielded good agreement with plate experimental strain data in attached (unloaded) and loaded conditions. The results highlight the importance of pre-tensioning in modeling plate attachment using non-locking screws.

Fracture morphology and biomechanical characteristics of Pauwels III femoral neck fractures in young adults

BACKGROUND

Pauwels classification, which categorizes types of femoral neck fractures, cannot fully reflect the three-dimensional characteristics of this injury. The purpose of our study was to determine the morphological characteristics of Pauwels III fractures through computed tomography image analysis and summarize the relevant biomechanical characteristics of different morphological fractures.

METHODS

We retrospectively reviewed a total of 209 patients diagnosed with Pauwels type III femoral neck fractures. Fracture reduction was simulated based on mirror symmetry of the bilateral femur by Mimics. The fracture angle was measured and subtypes were defined. Biomechanical characteristics were compared by finite element analysis and validated using a biomechanical experiment, which was performed on a cadaveric sample.

RESULTS

Pauwels III femoral neck fractures can be divided into three subtypes: anterior, posterior, and classical. The proportion of three subtypes was 28.71%, 67.46%, and 3.82%, respectively. The anterior subtype showed the lowest axial stiffness but highest implant and bone stress. High stress distributions was concentrated on the screw-bone interface and screw-plate connections.

CONCLUSIONS

Biomechanical differences across the three subtypes of Pauwels III femoral neck fractures could increase our understanding of the biomechanical characteristics that underlie the Pauwels type III femoral neck fractures (such as, three-dimensional morphology and the stress distribution of bone and implant) that have been associated with high failure rates.

[Current status and progress of locking plate in the treatment of distal femoral comminuted fracture]

OBJECTIVE

To review the current status and progress of locking plate for the treatment of distal femoral comminuted fractures.

METHODS

The related literature was extensively reviewed to summarize the current status and progress in the treatment of distal femoral comminuted fracture with locking plate from four aspects: the current treatment situation, the shortcomings of locking plate and countermeasures, the progress of locking technology, locking plate and digital orthopedic technology.

RESULTS

Treatment of distal femoral comminuted fractures is challenging. Locking plates, the most commonly used fixation for distal femoral comminuted fractures, still face a high rate of treatment failure. Double plates can improve the mechanical stability of comminuted fractures, but specific quantitative criteria are still lacking for when to choose double plates for fixation. The far cortial locking screw has shown good application value in improving the micro-movement and promoting the growth of callus. The biphasic plating is a development of the traditional locking plate, but needs further clinical examination. As an auxiliary means, digital orthopedic technology shows a good application prospect.

CONCLUSION

The inherent defect of locking plate is a factor that affects the prognosis of distal femoral comminuted fracture. The optimization of locking technology combined with digital orthopedic technology is expected to reduce the failure rate of treatment of distal femoral comminuted fracture.

[Research on the nature of micromovement and the biomechanical staging of fracture healing]

Objective

To explore the nature of micromovement and the biomechanical staging of fracture healing.

Methods

Through literature review and theoretical analysis, the difference in micromovement research was taken as the breakthrough point to try to provide a new understanding of the role of micromovement and the mechanical working mode in the process of fracture healing.

Results

The process of fracture healing is the process of callus generation and connection. The micromovement is the key to start the growth of callus, and the total amount of callus should be matched with the size of the fracture space. The strain at the fracture end is the key to determine the callus connection. The strain that can be tolerated by different tissues in the fracture healing process will limit the micromovement. According to this, the fracture healing process can be divided into the initiation period, perfusion period, contradiction period, connection period, and physiological period, i.e., the biomechanical staging of fracture healing.

Conclusion

Biomechanical staging of fracture healing incorporates important mechanical parameters affecting fracture healing and introduces the concepts of time and space, which helps to understand the role of biomechanics, and its significance needs further clinical test and exploration.

Comparison of a standardized four-point bending test to an implant system test of an osteosynthetic system under static and dynamic load condition

Current test standards of osteosynthetic implants examine the bone plate and screw separately leading to unrealistic load scenarios and unknown performance of the system as a whole, which prevents the identification of characteristic failures in clinical use. A standardized static and dynamic four-point bending test (ASTM F382) was performed on a bone plate. Based on that standard, an advanced implant system test (IST) was designed and performed to test a mechanical construct consisting of a bone plate, screws and an artificial bone substitute out of Polyoxymethylene (POM). The test object was an osteosynthetic system to treat fractured ulna bones. Both results of the conventional and advanced test method were analyzed and compared to one another. The static results show a similar yield point (YP) relative to the bending moment with just 9% difference. Dynamic results show a bi-phasic behavior of the displacement vs. cycle data for the IST. The secondary phase can be defined as a constantly increasing plastic deflection or ratcheting effect quantified by its slope in mm per one million cycles, leading to a 10 times higher slope for the IST than the conventional test. The IST has a high impact on the test results and the resultant interpretation of the mechanical behavior of the osteosynthetic system. A constantly increasing plastic deflection might lead to fatigue failures and to a loss of the mechanical durability. The development of new standardizations referring to the whole system within reasonable boundary conditions of individual biomechanical applications is crucial for high quality mechanical analysis.

A comparative study of 3D printing and heat-compressing methods for manufacturing the thermoplastic composite bone fixation plate: Design, characterization, and in vitro biomechanical experimentation

Metallic bone fixations, due to their high rigidity, can cause long-term complications. To alleviate metallic biomaterials' drawbacks, in this research new Glass Fiber/Polypropylene (GF/PP) composite internal fixations were developed, and an investigation of their mechanical behavior was performed through in vitro biomechanical experiments. Short randomly oriented, long unidirectional prepreg, and long unidirectional fiber yarn were considered as reinforcements, and the effects on their mechanical properties of different manufacturing processes, that is, 3D printing and heat-compressing, were investigated. The constructed fixation plates were tested in the transversely fractured diaphysis of bovine tibia under axial compression loading. The overall stiffness and the Von Mises strain field of the fixation plates were obtained within stable and unstable fracture conditions. The samples were loaded until failure to determine their failure loads, strains, and mechanisms. Based on the results, the GF/PP composite fixation plates can provide adequate interfragmentary movement to amplify bone ossification, so they can provide proper support for bone healing. Moreover, their potential for stress shielding reduction and their load-bearing capacity suggest their merits in replacing traditional metallic plates.

A new porous fixation plate design using the topology optimization

Fixation plates are used to accelerate the biological healing process in the damaged area by providing mechanical stabilization for fractured bones. However, they may cause mechanical and biological complications such as aseptic loosening, stress shielding effect and necrosis during the treatment process. The aim of this study, therefore, was to reduce mechanical and biological complications observed in conventional plate models. For this purpose, an optimum plate geometry was obtained using the finite element based topology optimization approach. An optimum and functionally graded porous model were obtained for the plates used for transverse fractures of diaphysis in long bones. This model was combined with a functional graded porous cage structure, and thus a new generation porous implant model was proposed for fixation plates. In order to determine the performance of the optimum plate model, it was produced by additive manufacturing. Three models; i.e. conventional, optimum and porous fixation plates were statically tested, and they were compared experimentally and numerically using the finite element analysis (FEA). The porous model can be considered as the most suitable option since it requires less invasive inputs, and might lead minimum necrosis formation due to having lesser contact surface with the bone.

Can Optimizing the Mechanical Environment Deliver a Clinically Significant Reduction in Fracture Healing Time?

The impact of the local mechanical environment in the fracture gap on the bone healing process has been extensively investigated. Whilst it is widely accepted that mechanical stimulation is integral to callus formation and secondary bone healing, treatment strategies that aim to harness that potential are rare. In fact, the current clinical practice with an initially partial or non-weight-bearing approach appears to contradict the findings from animal experiments that early mechanical stimulation is critical. Therefore, we posed the question as to whether optimizing the mechanical environment over the course of healing can deliver a clinically significant reduction in fracture healing time. In reviewing the evidence from pre-clinical studies that investigate the influence of mechanics on bone healing, we formulate a hypothesis for the stimulation protocol which has the potential to shorten healing time. The protocol involves confining stimulation predominantly to the proliferative phase of healing and including adequate rest periods between applications of stimulation.

Hybrid locked medial plating in dual plate fixation optimizes the healing of comminuted distal femur fractures: A retrospective cohort study

OBJECTIVES

Dual plate fixation has been reported to be effective in the treatment of comminuted distal femur fractures (DFFs). However, optimized use of the medial plate and screws is less studied. This study aimed to evaluate the effect of a hybrid configuration of the medial plate in dual plate fixation of comminuted DFFs in promoting fracture healing.

MATERIALS AND METHODS

We retrospectively analyzed 62 patients with comminuted DFFs (AO/OTA 33-A3/33-C2/33-C3) from January 2015 to March 2020, who were either fixed with lateral locked plating augmented with hybrid locked medial plating (LP-HLMP, n = 32) or lateral locked plating (LLP, n = 30) alone. Specifically, compression screws were applied in the middle of the medial plate and flanked by locking ones at both ends. Baseline characteristics, radiological and clinical outcomes were reviewed and analyzed. Multivariate logistic regression analysis was used to identify predictive factors for early fracture healing, and risk factors for delayed union/nonunion.

RESULTS

Demographics including age, gender, smoking, diabetes, and injury mechanism were comparable between the two groups. Reduction quality was better in the LP-HLMP group (p < 0.001). Although the LP-HLMP group experienced longer duration of surgery (125 min vs. 100 min, p < 0.001), sign of healing at 3 months was more obvious in this group (75%, 24/32 vs. 30%, 9/30; p < 0.001). The LP-HLMP group also presented with higher union rate (93.8%, 30/32 vs. 56.7%, 17/30; p = 0.001) and lower reoperation rate (0%, 0/32 vs. 13.3%, 4/30; p = 0.049). Kolment score showed no statistical significance between the two groups. Multivariate analysis revealed that younger age (< 60 years) (OR 5.99, 95%CI 1.16 - 31.03; p = 0.001) and LP-HLMP fixation (OR 45.90, 95% CI 4.78 - 440.56; p = 0.001) predict early healing; while smoking (OR 17.80, 95% CI 2.41 - 131.49; p = 0.01) and fracture translation (OR 3.49, 95% CI 1.46 - 8.32; p = 0.01) were identified as risk factors for delayed union/nonunion.

CONCLUSION

Hybrid locked medial plating in this study favors the healing of comminuted DFFs and reduces reoperation. Additionally, smoking and suboptimal reduction (translation) predict delayed union/nonunion.

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.

The Clinical and Radiological Evaluation of Far Cortex Locking Plate in Distal Femur Fractures

Introduction Locking plates in distal femur fractures were associated with a high rate of non-union and hardware failure. To overcome these drawbacks far cortex locking (FCL) concept was introduced. It is a novel bridge plating strategy to enhance interfragmentary motion for the promotion of secondary bone healing while retaining sufficient construct strength. The present study evaluated the effects of diaphyseal FCL fixation on fracture healing for periarticular locking plates used for fixation of distal femur fractures.  Materials and methods Our cohort was of 11 consecutive patients who presented to emergency after distal femur fracture and underwent surgery with the FCL plate between January 2015 and January 2016. Clinical (KOOS) and radiological evaluation of all patients was done to look for knee scores and union. Also, other complications like infection, non-union, painful hardware, implant failure were recorded  Results No non-union or hardware failure was observed in our cohort of 11 patients. Early callus formation was seen and partial weight-bearing was started at an average of 6 weeks (5-8 weeks). Average time to clinical healing was 10 weeks (8-13 weeks) whereas radiographic union was seen at 16 weeks (14-17 weeks). One patient with an open fracture had superficial surgical wound infection which healed uneventfully after one debridement and with IV antibiotics. The average knee injury and osteoarthritis outcome score (KOOS) at final follow-up was 91 (87-95) in our cohort. Conclusion FCL is an effective method to reduce construct stiffness, promote early callus formation, decrease non-union rate and achieve biological healing while retaining sufficient strength to prevent hardware failure.

Biomechanical evaluation of glass fiber/polypropylene composite bone fracture fixation plates: Experimental and numerical analysis

Little is known about the impact behavior of composite fixation plate used in the fracture healing of long bones diaphysis. Hence, this study examined polypropylene composite fixation plates using different glass fibers and measured their biomechanical responses under axial impact loading experimentally and numerically. Short randomly oriented, long unidirectional prepregs and fiber yarn of glass were considered as reinforcements, and fixation plates were fabricated through two different heat-compressing and 3D printing processes. Furthermore, assessing the fixation plate structures impact behavior was carried out using in vitro impact test and finite element analysis (FEA). Impact damping behavior, damage mechanisms, and stress and strain pattern of the composite fixation plate structures were obtained under various bone fractures and impact energies. The impact load-time responses and the failure mechanisms demonstrated that fixation plate structures with more plastic behavior and lower stiffness could act as an initial shock absorber and dampen the transmission of axial impact load by distributing the impact energy over time. Therefore, considering the ability of stress shielding and adequate interfragmentary movement which amplifies bone ossification, the proposed Glass Fiber/PP (GF/PP) composite fixation plates could serve as a proper alternative in orthopedics.

Biomechanical optimization of the far cortical locking technique for early healing of distal femur fractures

This finite element study optimized far cortical locking (FCL) technology for early callus formation in distal femur fracture fixation with a 9-hole plate using FCL screws proximal to, and standard locking screws distal to, the fracture. Analyses were done for 120 possible FCL screw configurations by varying FCL screw distribution and number. A hip joint force of 700 N (i.e. 100% x body weight) was used, which corresponds to a typical 140 N "toe-touch" foot-to-ground force (i.e. 20% x body weight) suggested to patients immediately after surgery. Increased FCL screw distribution (i.e. shorter plate working length) caused a decrease at the medial side and an increase at the lateral side of the axial interfragmentary motion (AIM), mildly affected shaft and condylar cortex Von Mises max stress (σ_MAX), increased plate σ_MAX, and decreased shaft FCL screw and condylar locking screw σ_MAX. Increased FCL screw number decreased AIM and σ_MAX on the shaft cortex, condylar cortex, plate, and FCL screws, but not condylar screws. The optimal FCL screw configuration had 3 FCL screws in plate holes #1, 5, and 6 (proximal to distal) for optimal AIM of 0.2 - 1 mm and reduce shear fracture motion, thereby encouraging early callus formation.

Influence of gap distance between bone and plate on structural stiffness and parallel interfragmental movement in far-cortical locking technique - a biomechanical study

Sufficient interfragmental movement is the key to successful fracture healing in the theory of secondary bone healing. The far-cortical locking technique enables both stiffness reduction and parallel motion for ideal callus formation and fracture healing, but the influence of plate-bone gap on the performance of far-cortical locking technique remains unclear. The current study conducted a series of finite element analyses with mechanical validation to clarify this issue. Plate-bone gaps were assigned by 1, 2, 3, and 4 mm in a simulated mid-shaft fracture model fixed with locking plate and six semi-rigid locking screws. Axial compressive load to 500 N was applied to the fixation structure to evaluate the structural stiffness, pattern of interfragmental movement (parallel motion), and stresses on the screws. Results revealed the increased plate-bone gaps reduced the structural in order (315.3, 288.8, 264.9, and 243.4 N/mm). Tilting angles for determining parallel interfragmental movement (1.58°-1.85°) and stresses on semi-rigid screws for evaluating implant safety were not severely altered. Greater stresses were found on the screws adjacent to the fracture site in all simulated models. The current study suggested that 1 mm gap between the locking plate and the bone shall be ideal in view of parallel motion achieved balanced callus formation in far-cortical locking technique. Issue of reducing structural stiffness with limited plate-bone gap distance should be further investigated.

Assessment of the efficacy of the far cortical locking technique in proximal humeral fractures: a comparison with the conventional bi-cortical locking technique

Background

Locking plate fixation is one of the treatment strategies for the management of proximal humeral fractures. However, stiffness after locking plate fixation is a clinical concern. The mechanical stiffness of the standard locking plate system may suppress the interfragmentary motion necessary to promote secondary bone healing by callus formation. The far cortical locking (FCL) technique was developed to address this limitation in 2005. FCL increases construct flexibility and promotes callus formation. Our study aimed to evaluate the clinical and radiological outcomes of the FCL technique when implemented in proximal humeral fracture management. Furthermore, we compared the surgical outcomes of FCL with those of the conventional bicortical locking (BCL) screw fixation technique.

Methods

Forty-five consecutive patients who had undergone locking fixation for proximal humeral fractures were included in this study. A proximal humeral locking plate (PHILOS) system with BCL screw fixation was used in the first 27 cases, and the periarticular proximal humeral locking plate with FCL screw fixation was used in the final 18 consecutive cases. Functional capacity was assessed using the constant score, American Shoulder and Elbow Surgeons (ASES) score, and range of motion. Radiographic outcomes were evaluated using the Paavolainen method of measuring the neck-shaft angle (NSA).

Results

No significant differences in clinical outcomes (ASES score, constant score, and range of motion) were found between the two groups. The union rate at 12 weeks was significantly higher in the FCL group (94.4%) than in the BCL group (66.7%, p = 0.006). No significant differences in NSA were found between the two treatment strategies. The complication rate was not significantly different between the two groups.

Conclusions

When implemented in proximal humeral fractures, the FCL technique showed satisfactory clinical and radiological outcomes as compared with the conventional BCL technique. The bone union rate at 12 weeks after surgery was significantly higher in the FCL group than in the BCL group. However, no significant difference in the final bone union rate was found between the two groups.

Biomechanical design using in-vitro finite element modeling of distal femur fracture plates made from semi-rigid materials versus traditional metals for post-operative toe-touch weight-bearing

This proof-of-concept study designs distal femur fracture plates from semi-rigid materials vs. traditional metals for toe-touch weight-bearing recommended to patients immediately after surgery. The two-fold goal was to (a) reduce stress shielding (SS) by increasing cortical bone stress thereby reducing the risk of bone absorption and plate loosening, and (b) reduce delayed healing (DH) via early callus formation by optimizing axial interfragmentary motion (AIM). Finite element analysis was used to design semi-rigid plates whose elastic moduli E ensured plates permitted AIM of 0.2 - 1 mm for early callus formation. A low hip joint force of 700 N (i.e. 100% x body weight) was applied, which corresponds to a typical 140 N toe-touch foot-to-ground force (i.e. 20% x body weight) recommended to patients after surgery. Analysis was done using 2 screw materials (steel or titanium) and types (locked or non-locked). Steel and titanium plates were also analyzed. Semi-rigid plates (vs. metal plates) had lower overall femur/plate construct stiffnesses of 508 - 1482 N/mm, higher cortical bone stresses under the plate by 2.02x - 3.27x thereby reducing SS, and lower E values of 414 - 2302 MPa to permit AIM of 0.2 - 1 mm thereby reducing DH.

Biomechanical comparison of distal femoral fracture fixation: Analysis of non-locked, locked, and far-cortical locked constructs

To assess whether far-cortical locking (FCL) screws alter the fracture site strain environment and allow shorter bridge plate constructs for supracondylar femoral fractures, we tested the fracture site displacement under force of synthetic left femora with a 5-cm metaphyseal fracture gap, modeling comminution. Five models of nine constructs were tested (three types of diaphyseal screws [nonlocking, locking, and FCL] and two plate lengths [13 holes and 5 holes]). Long plate models using three or four diaphyseal screws (working length 13.5 or 7.5 cm, respectively) were compared with short plates with three diaphyseal screws (working length 7.5 cm). Models were loaded axially and torsionally; 100 cycles in random order. Primary outcome measures were axial and torsional fracture site stiffness. FCL screws decreased rotational stiffness 19% (P < .01) compared with baseline nonlocking screws in the same plate and working length construct, mirroring the effect (20% decrease in stiffness, P < .01) of nearly doubling the nonlocking construct working length (7.5-13.5 cm). Similarly, FCL screws decreased axial stiffness 23% (P < .01) in the same baseline comparison. Fracture site displacement under loading comparable to a long working length nonlocked plate construct was achieved using a shorter FCL plate construct. By closely replicating the biomechanical properties of a long plate construct, a fracture site strain environment considered favorable in promoting fracture healing might still be achievable using a shorter plate length. Clinical Significance: It might be possible to optimize fracture site strain environment and displacement under loading using shorter FCL plate constructs. Orthopaedic Research Society. Published by Wiley Periodicals, Inc. J Orthop Res 00:00-00, 2020.

A biomechanical matched-pair comparison of two different locking plates for tibial diaphyseal comminuted fracture: carbon fiber-reinforced poly-ether-ether-ketone (CF-PEEK) versus titanium plates

Background

Several methods have been proposed to reduce plate construct stiffness and promote secondary bone healing. In this study, we explored the stiffness and strength of the new carbon fiber-reinforced poly-ether-ether-ketone (CF 50) plate compared with the titanium alloy plate (Ti6Al4V).

Methods

Titanium and CF-PEEK locking plates were tested in a tibial non-osteoporotic diaphyseal comminuted fracture model to determine construct stiffness in axial compression, torsion, and bending. Subsequently, constructs were loaded until construct failure to determine construct strength.

Results

Relative to the titanium locking plate, the stiffness of the CF-PEEK locking plate was 6.8% and 30.8% lower in 200 N and 700 N axial compression, respectively (P < 0.05), 64.9% lower in torsion (P < 0.05), and 48.9% lower in bending (P < 0.05). The strength of the CF-PEEK locking plate was only 2.6% lower under axial compression, 7.8% lower in torsion, and 4.8% lower in bending than the titanium locking plate (P > 0.05).

Conclusions

The CF-PEEK locking plate significantly reduced axial, torsion, and bending stiffness compared with the titanium locking plate. Nonetheless, axial, torsional, and bending strength showed only a modest reduction. Considering its other advantages, which include radiolucency and artifact-free imaging, the CF-PEEK locking plate therefore deserves further clinical investigation.

Biomechanical assessment of screw safety between far cortical locking and locked plating constructs

With the emerging concerns for more flexible and less stiff bridge constructs in the interest of stimulating bone healing, the technique of far cortical locking has been designed to reduce the stiffness of locked plating (LP) constructs while retaining construct strength. This study utilized simulation with diaphyseal bridge plating biomechanical models to investigate whether far cortical locking causes larger screw fracture risk than LP during rehabilitation. The fracture risk of the screws in the far cortical locking constructs increases in the non-osteoporotic and osteoporotic diaphysis compared with the screws in the LP constructs.

Effects of Bone-Plate Material on the Predicted Stresses in the Tibial Shaft Comminuted Fractures: A Finite Element Analysis

PURPOSE

In this research, low modulus carbon fiber (CF)-reinforced polyetheretherketone composite plates (CF-PEEK plates) were compared with traditional metal plates using finite element analysis to establish a reference for clinical application.

MATERIAL AND METHODS

Plates of stainless steel, titanium alloy (Ti6Al4V), or CF-PEEK with different carbon fiber reinforcement ratios (CF30, CF50, and CF60) were used to fix the tibial shaft comminuted fracture. The maximum stress, the maximum displacement of fracture and the stress shielding of cortex bone were analyzed.

RESULTS

Under 200 N axial compression, the maximum displacement was measured in the CF30 plate (4.62 mm) and the minimum in the stainless steel plate (0.23 mm). The stress shielding rates of stainless steel, titanium, CF30, CF50, and CF60 plates were 59.4%, 54.4%, 23.75%, 48.75% and 66.25%. Under 700 N axial compression, the internal fixation by the CF30 plate failed. Among the other 4 plates, the maximum displacement was measured in the CF50 plate (2.52 mm) and the minimum in the stainless steel plate (0.78 mm). The stress shielding rate of plates made of stainless steel, titanium, CF50, and CF60 were 57.1%, 52.0%, 48.1%, and 67.8%.

CONCLUSIONS

CF50 plates can be safely used in the tibial shaft comminuted fracture. The micromotion in the CF50 and CF60 plate was more beneficial to callus formation and fracture healing. The stress shielding of the cortex bone under the CF50 plate was the lowest. The finite element analysis indicated that the CF-PEEK material is worthy of further study because of its biomechanical advantages.

Variable Fixation Technology Provides Rigid as Well as Progressive Dynamic Fixation: A Biomechanical Investigation

BACKGROUND

A new locking-screw technology, the Variable Fixation Locking Screw (VFLS; Biomech Innovations), was developed with the aim of promoting secondary fracture-healing. The VFLS features a resorbable sleeve that progressively decreases its mechanical properties and mass during the fracture-healing time. In this study, we investigated whether the VFLS can provide rigid as well as progressive dynamic fixation.

METHODS

The interfragmentary stability provided by the VFLS was tested in a simulated fracture-gap model and compared with that provided by standard locking or by a combination of both technologies under compression and torsional loading. Tests were performed with an intact sleeve (initial condition) and after its chemical dissolution. An optical measurement system was used to characterize interfragmentary movements.

RESULTS

The axial stiffness did not differ significantly among groups in the initial condition. Sleeve resorption significantly decreased construct stiffness. The torsional stiffness of the samples instrumented with the VFLS was lower than that of the control group. The degradation of the sleeve resulted in a significant increase in axial displacement recorded at both the cis and trans cortices. In samples featuring combined technologies, this increase was about 12% to 20% at the trans cortex and about 50% to 60% at the cis cortex. In samples featuring VFLS technology only, this increase was about 20% to 37% at the trans cortex and about 70% to 125% at the cis cortex.

CONCLUSIONS

The initial stability offered by the VFLS is equivalent to that of standard locking-screw technology. The resorption of the degradable sleeve leads to effective and reproducible fracture-gap dynamization, progressively varying the way the fracture gap is strained and the magnitude of the strain.

CLINICAL RELEVANCE

The VFLS provides rigid and progressive dynamic fixation in vitro. Such variable stability might have beneficial effects in terms of triggering and boosting secondary fracture-healing.