Machining and Accuracy Studies for a Tibial Knee Implant Using a Force-Controlled Robot

The current state of robotics in total knee arthroplasty

Robotic total knee arthroplasty (TKA) has demonstrated improved component positioning and a reduction of alignment outliers with regard to pre-operative planning.

Early robotic TKA technologies were mainly active systems associated with significant technical and surgical complications.

Current robotic TKA systems are predominantly semi-active with additional haptic feedback which minimizes iatrogenic soft tissue injury compared to conventional arthroplasty and older systems.

Semi-active systems demonstrate advantages in terms of early functional recovery and hospital discharge compared to conventional arthroplasty.

Limitations with current robotic technology include high upfront costs, learning curves and lack of long-term outcomes.

The short-term gains and greater technical reliability associated with current systems may justify the ongoing investment in robotic technology.

Further long-term data are required to fully ascertain the cost-effectiveness of newer robotic systems.

Cite this article: EFORT Open Rev 2021;6:270-279. DOI: 10.1302/2058-5241.6.200052

EXPERIMENTAL ANALYSIS, STATISTICAL MODELING AND OPTIMIZATION OF EFFECTIVE PARAMETERS ON SURFACE QUALITY IN CORTICAL BONE MILLING PROCESS

Knee joint surgery for artificial joint replacement is common in orthopedic surgeries. In this operation, there is a need to prepare the surface of the cortical bone for mounting the artificial joint. Therefore, milling process is frequently performed. Since the surgeon should be careful not to hurt bone tissue and neurons and also minimize waste of blood, the operation should be performed in the shortest possible time. This study, for the first time, focuses on modeling and optimization of effective parameters of bone milling including cutting speed, feed rate and tool diameter on surface roughness and material removal rate using response surface method. Results showed that in order to achieve maximum surface quality, minimum feed rate, maximum tool diameter and down milling procedure should be selected. On the other hand, the maximum material removal rate coincides with maximum feed rate and tool diameter. Therefore, cutting speed of 3000[Formula: see text]rpm, feed rate of 50[Formula: see text]mm/min, tool diameter of 5[Formula: see text]mm and down milling procedure can satisfy both high surface quality and high material removal rate.

A Multiaxis Programmable Robot for the Study of Multibody Spine Biomechanics Using a Real-Time Trajectory Path Modification Force and Displacement Control Strategy

Robotic testing offers potential advantages over conventional methods including coordinated control of multiple degrees of freedom (DOF) and enhanced fidelity that to date have not been fully utilized. Previous robotic efforts in spine biomechanics have largely been limited to pure displacement control methods and slow quasi-static hybrid control approaches incorporating only one motion segment unit (MSU). The ability to program and selectively direct single or multibody spinal end loads in real-time would represent a significant step forward in the application of robotic testing methods. The current paper describes the development of a custom programmable robotic testing system and application of a novel force control algorithm. A custom robotic testing system with a single 4 DOF serial manipulator was fabricated and assembled. Feedback via position encoders and a six-axis load sensor were established to develop, program, and evaluate control capabilities. A calibration correction scheme was employed to account for changes in load sensor orientation and determination of spinal loads. A real-time force control algorithm was implemented that employed a real-time trajectory path modification feature of the controller. Pilot tests applied 3 Nm pure bending moments to a human cadaveric C2–T1 specimen in flexion and extension to assess the ability to control spinal end loads, and to compare the resulting motion response to previously published data. Stable accurate position control was achieved to within ±2 times the encoder resolution for each axis. Stable control of spinal end body forces was maintained to within a maximum error of 6.3 N in flexion. Sagittal flexibility data recorded from rostral and caudally placed six-axis load sensors were in good agreement, indicating a pure moment loading condition. Individual MSU rotations were consistent with previously reported data from nonrobotic protocols. The force control algorithm required 5–10 path iterations before converging to programmed end body forces within a targeted tolerance. Commercially available components were integrated to create a fully programmable custom 4 DOF gantry robot. Individual actuator performance was assessed. A real-time force control algorithm based on trajectory path modification was developed and implemented. Within a reasonable number of programmed path iterations, good control of spinal end body forces and moments, as well as a motion response consistent with previous reported data, were obtained throughout a full physiologic flexion-extension range of motion in the human subaxial cervical spine.

Robot-assisted implantation improves the precision of component position in minimally invasive TKA

Minimally invasive and robot-assisted procedures have potential advantages when used for total knee arthroplasty (TKA). The purpose of this cadaveric study was to examine whether robot-assisted minimally invasive procedures improve TKA alignment after modifying the robotic techniques and instruments. Total knee arthroplasties were performed on 10 pairs of fresh cadaveric femora. Ten knees were replaced using the robot-assisted minimally invasive technique and 10 using the conventional minimally invasive technique. After prosthesis implantation, limb and prosthesis alignments were investigated by measuring mechanical axis deviation, femoral and tibial sagittal and coronal inclination, and femoral rotational alignment with 3-dimensional computed tomography scans. Postoperative alignment accuracy of the implanted prostheses was better in the robot-assisted minimally invasive TKA group than in the conventional minimally invasive TKA group as judged by the rotational alignment of the femoral component (0.7°±″.3° vs 3.6°±2.2°, respectively) and the tibial component sagittal angle (7.8°±1.1° vs 5.5°±3.6°, respectively). One sagittal inclination outlier for the tibial side existed in the robotic minimally invasive TKA group, and 2 outliers for the mechanical axis, 2 for the tibial side sagittal inclination, and 2 for the femoral rotational alignment existed in the conventional minimally invasive TKA group. Higher implanted prostheses accuracy and fewer outliers in postoperative radiographic alignments can be attained with robot-assisted TKA. Minimally invasive TKA in combination with an improved robot-assisted technique is an alternative option to compensate for the shortcomings of conventional minimally invasive TKA.

Comparison of robot-assisted and conventional total knee arthroplasty: a controlled cadaver study using multiparameter quantitative three-dimensional CT assessment of alignment

INTRODUCTION

A functional total knee replacement has to be well aligned, which implies that it should lie along the mechanical axis and in the correct axial and rotational planes. Incorrect alignment will lead to abnormal wear, early mechanical loosening, and patellofemoral problems. There has been increased interest of late in total knee arthroplasty with robotic assistance. This study was conducted to determine whether robot-assisted total knee arthroplasty is superior to the conventional surgical method with regard to the precision of implant positioning.

MATERIALS AND METHODS

Twenty knee replacements, comprising ten robot-assisted procedures and ten conventional operations, were performed on ten cadavers. Two experienced surgeons performed the surgeries. Both procedures on each cadaver were performed by the same surgeon. The choice of which procedure was to be performed first was randomized. Following implantation of the prosthesis, the mechanical axis deviation, femoral coronal angle, tibial coronal angle, femoral sagittal angle, tibial sagittal angle, and femoral rotational alignment were measured via 3D CT scanning. These variables were then compared with the preoperatively planned values.

RESULTS

In the knees that underwent robot-assisted surgery, the mechanical axis deviation ranged from -1.94° to 2.13° (mean: -0.21°), the femoral coronal angle from 88.08° to 90.99° (mean: 89.81°), the tibial coronal angle from 89.01° to 92.36° (mean: 90.42°), the tibial sagittal angle from 81.72° to 86.24° (mean: 83.20°), and the femoral rotational alignment from 0.02° to 1.15° (mean: 0.52°) in relation to the transepicondylar axis. In the knees that underwent conventional surgery, the mechanical axis deviation ranged from -3.19° to 3.84° (mean: -0.48°), the femoral coronal angle from 88.36° to 92.29° (mean: 90.50°), the tibial coronal angle from 88.15° to 91.51° (mean: 89.83°), the tibial sagittal angle from 80.06° to 87.34° (mean: 84.50°), and the femoral rotational alignment from 0.32° to 4.13° (mean: 2.76°) in relation to the transepicondylar axis. In the conventional knee replacement group, there were two instances of outliers outside the range of 3° varus/valgus for the mechanical axis deviation. The robot-assisted knee replacements showed significantly superior femoral rotational alignment results compared with conventional surgery (p = 0.006). There was no statistically significant difference between robot-assisted and conventional total knee arthroplasty with regard to the other variables. All the measurements showed high intra-observer and inter-observer reliability.

CONCLUSION

Robot-assisted total knee arthroplasty showed excellent precision in the sagittal and coronal planes of the 3D CT scan. In particular, the robot-assisted technique showed better accuracy in femoral rotational alignment compared to the conventional surgery, despite the fact that the surgeons who performed the operations were more experienced and familiar with the conventional method than with robot-assisted surgery. It can thus be concluded that robot-assisted total knee arthroplasty is superior to conventional total knee arthroplasty.

Simultaneous bilateral total knee arthroplasty with robotic and conventional techniques: a prospective, randomized study

PURPOSE

The authors performed this study to compare the outcomes of robotic-assisted and conventional TKA in same patient simultaneously. It was hypothesized that the robotic-assisted procedure would produce better leg alignment and component orientation, and thus, improve patient satisfaction and clinical and radiological outcomes.

METHODS

Thirty patients underwent bilateral sequential total knee replacement. One knee was replaced by robotic-assisted implantation and the other by conventional implantation.

RESULTS

Radiographic results showed significantly more postoperative leg alignment outliers of conventional sides than robotic-assisted sides (mechanical axis, coronal inclination of the femoral prosthesis, and sagittal inclination of the tibial prosthesis). Robotic-assisted sides had non-significantly better postoperative knee scores and ROMs. Robotic-assisted sides needed longer operation times (25 min, SD ± 18) and longer skin incisions. Nevertheless, postoperative bleeding was significantly less for robotic-assisted sides.

CONCLUSION

The better alignment accuracy of robotic TKA and the good clinical results achieved may favorably influence clinical and radiological outcomes.

Morphology of the tibial insertion of the posterior cruciate ligament

BACKGROUND

It has been demonstrated that double-bundle reconstruction of the posterior cruciate ligament restores knee kinematics better than does single-bundle reconstruction. The objective of this study was to identify the tibial insertion site of the posterior cruciate ligament and the related osseous landmarks to help guide surgeons in the performance of an anatomical double-bundle reconstruction of the posterior cruciate ligament.

METHODS

Twenty-one unpaired human cadaver knees were evaluated. The geometric data and surface features of the tibial insertion site of the posterior cruciate ligament and its bundles were studied with macroscopic observation and with three-dimensional laser photography.

RESULTS

The mean surface areas (and standard deviations) of the anterolateral and posteromedial insertion sites were 93.1+/-16.6 mm2 and 150.8+/-31.0 mm2, respectively, and the distance between their centers was 8.2+/-1.3 mm. The mean length and width of the anterolateral insertion site were 7.8+/-1.5 mm and 9.2+/-1.6 mm, and the mean length and width of the posteromedial insertion site were 9.4+/-1.4 mm and 15.0+/-2.7 mm. The average distances from the anterior and medial margins of the tibial plane to the center of the anterolateral insertion, defined as percentage ratios of the anteroposterior and mediolateral dimensions, were 83.4%+/-3.4% and 47.1%+/-1.9%, respectively, and the average distances from the anterior and medial margins of the tibial plane to the center of the posteromedial insertion were 95.5%+/-1.9% and 43.8%+/-2.2%. A notable change in angle, of >10 degrees, was observed between the anterolateral and posteromedial slopes in sixteen of the twenty-one knees. The average angle between the anterolateral and posteromedial slopes was 14.5 degrees+/-6.4 degrees.

CONCLUSIONS

The tibial insertion site of the posterior cruciate ligament and its bundles is very complex. However, the shapes and positions of the insertion sites of the two bundles are consistent in that they are located in different planes on the posterior intercondylar fossa. We noted a consistent change in slope between the tibial insertion sites of the anterolateral and posteromedial bundles.

Robot-assisted total knee arthroplasty

Increasing evidence suggests performing total knee arthroplasty using computer navigation can lead to more accurate surgical positioning of the components and knee alignment compared to a conventional operating technique without computer assistance. The use of robotic technology could theoretically take this accuracy one level further because it uses navigation in combination with ultimate mechanical precision, which could eliminate or reduce the inevitable margin of error during mechanical preparation of the bony cuts of total knee arthroplasty by the surgeon. We prospectively followed 25 consecutive cases using an active surgical robot. The minimum followup was 5.1 years (mean, 5.5 years; range, 5.1-5.8 years). Our results demonstrate excellent implant positioning and alignment was achieved within the 1 degree error of neutral alignment in all three planes in all cases. Despite this technical precision, the excessive operating time required for the robotic implantation, the technical complexity of the system, and the extremely high operational costs have led us to abandon this procedure and direct our interest more toward smart semiactive robotic systems.

LEVEL OF EVIDENCE

Level IV, therapeutic study. See the Guidelines for Authors for a complete description of levels of evidence.

Surgical navigation for total knee arthroplasty: A perspective

A new generation of surgical tools, known as surgical navigation systems, has been developed to help surgeons install implants more accurately and reproducibly. Navigation systems also record quantitative information such as joint range of motion, laxity, and kinematics intra-operatively. This article reviews the history of surgical navigation for total knee arthroplasty, the biomechanical principles associated with this technology, and the related clinical research studies. We describe how navigation has the potential to address three main challenges for total knee arthroplasty: ensuring excellent and consistent outcomes, treating younger and more physically active patients, and enabling less invasive surgery.

Praxiteles: a miniature bone-mounted robot for minimal access total knee arthroplasty

We have been working to develop a compact, accurate, safe, and easy-to-use surgical robot for minimally invasive total knee arthroplasty (TKA). The goal of our bone-mounted robot, named Praxiteles, is to precisely position a surgical bone-cutting guide in the appropriate planes surrounding the knee, so that the surgeon can perform the planar cuts manually using the guide. The robot architecture is comprised of 2 motorized degrees of freedom (DoF) whose axes of rotation are arranged in parallel, and are precisely aligned to the implant cutting planes with a 2 DoF adjustment mechanism. Two prototypes have been developed and tested on saw bones and cadavers--an initial one for open TKA surgery and a new version for MIS TKA, which mounts on the side of the knee. A novel bone-milling technique is also presented that uses passive guide and a side milling tool.

A semi-active milling procedure in view of preparing implantation beds in robot-assisted orthopaedic surgery

Bone cutting in total joint reconstructions requires a high accuracy to obtain a well-functioning and long-lasting prosthesis. Hence robot assistance can be useful to increase the precision of the surgical actions. A drawback of current robot systems is that they autonomously machine the bone, in that way ignoring the surgeon's experience and introducing a safety risk. This paper presents a semi-active milling procedure to overcome that drawback. In this procedure the surgeon controls robot motion by exerting forces on a force-controlled lever that is attached to the robot end effector. Meanwhile the robot constrains tool motion to the planned motion and generates a tool feed determined by the feed force that the surgeon executes. As a case study the presented milling procedure has been implemented on a laboratory set-up for robot-assisted preparation of the acetabulum in total hip arthroplasty. Two machining methods have been considered. In the first method the surgeon determines both milling trajectory and feed by the forces that he/she executes on the force-controlled lever. In the second method the cavity is machined contour by contour, and the surgeon only provides the feed. Machining experiments have shown that the first method results in large surface irregularities and is not useful. The second method, however, results in accurate cavity preparation and has therefore potential to be implemented in future robot systems.

Improved tibial cutting accuracy in knee arthroplasty

Initial stability and development of long-term fixation for cementless tibial components at the knee both depend on the accuracy of fit between implanted components and prepared bone surfaces. Tibial surfaces prepared for total knee replacement with conventional saw-blades and guides were shown by Toksvig-Larsen to vary by over 2 mm, from a flat surface at the point of maximum variation, and all points varied with a standard deviation of up to 0.4 mm. Surface cutting errors are caused by flexion of the saw-blade and blade angulation from the ideal alignment, due to poor guidance or control by the saw-block or guide. Most conventional knee instrumentation relies on flat surface or slotted cutting blocks, constraining the moving saw-blade against one or two guide surfaces. Improved cutting action was achieved by constraining the saw from the pivot point of the blade, and controlling motion of this constraint with parallel action slides. Using this saw-guide and an improved saw-blade, tibial cuts were made in mock arthroplasty procedures on twenty four cadaveric tibiae in mortuo. Analysis of Variance and Tukey's HSD test showed that the improved saw technique yielded significantly better flatness (p < 0.03) and greatly improved roughness (p < 0.0005).

Abrasive water jet cutting as a new procedure for cutting cancellous bone?In vitro testing in comparison with the oscillating saw

The quality of bone cuts is assessed by the accuracy and biological potency of the cut surfaces. Conventional tools (such as saws and milling machines) can cause thermal damage to bone tissue. Water jet cutting is nonthermal; that is, it does not generate heat. This study investigates whether the abrasive jet cutting quality in cancellous bone with a biocompatible abrasive is sufficient for the implantation of endoprostheses or for osteotomies. Sixty porcine femoral condyles were cut with an abrasive water jet and with an oscillating saw. alpha-lactose-monohydrate was used as a biocompatible abrasive. Water pressure (pW = 35 and 70 MPa) and abrasive feed rate (m = 0.5, 1, and 2 g/s) were varied. As a measure of the quality of the cut surface the cutting gap angle (delta) and the surface roughness (Ra) were determined. The surface roughness was lowest for an abrasive feed rate of m = 2 g/s (jet direction: 39 +/- 16 microm, advance direction: 54 +/- 22 microm). However, this was still significantly higher than the surface roughness for the saw group (jet direction: 28 +/- 12 microm, advance direction: 36 +/- 19 microm) (p < 0.001 for both directions). At both pressure levels the greatest cutting gap angle was observed for a mass flow rate of m = 1 g/s (pW = 35 MPa: delta = 2.40 +/- 4.67 degrees ; pW = 70 MPa: delta = 4.13 +/- 4.65 degrees), which was greater than for m = 0.5 g/s (pW = 35 MPa: delta = 1.63 +/- 3.89 degrees ; pW = 70 MPa: delta = 0.36 +/- 1.70 degrees) and m = 2 g/s (pW =70 MPa: delta = 0.06 +/- 2.40 degrees). Abrasive water jets are suitable for cutting cancellous bone. The large variation of the cutting gap angle is, however, unfavorable, as the jet direction cannot be adjusted by a predefined value. If it is possible to improve the cutting quality by a further parameter optimization, the abrasive water jet may be the cutting technique of the future for robotic usage.

Bone cutting errors in total knee arthroplasty

Although achieving precise implant alignment is crucial for producing good outcomes in total knee arthroplasty, the contribution of the bone-cutting process to overall variability has not been measured previously. Eight orthopaedic surgeons with varying amounts of total knee arthroplasty experience performed 85 resections on 19 cadaver femora and tibiae, and the planes of the resulting cut surfaces were compared with the guide planes. Varus-valgus alignment variability ranged from 0.4 degrees to 0.8 degrees SD for expert and trainee surgeons. Sagittal variability was approximately 1.3 degrees SD for both surgeon groups. Slotted cutting guides reduced the variability and eliminated the bias in the sagittal plane for experienced surgeons but did not improve significantly frontal plane alignment variability. Guide movement contributed 10% to 40% of the total cutting error, depending on cut and guide type.

How correctly does an intramedullary rod represent the longitudinal tibial axes?

In a robot-assisted procedure for preparing the tibia in total knee arthroplasty, developed in the authors' laboratory, an intramedullary rod is used to register the tibia. In 18 formalin-fixed tibias, the difference in orientation was calculated between the intramedullary rod and several longitudinal tibial axes used in clinical practice. This was done using roentgenstereophotogrammetric analysis. Three tibial axes and two insertion techniques were considered. In three-dimensional space, small differences between the axes are observed. The results showed a high standard deviation, indicating the importance of anatomic differences. In the frontal plane, the difference in orientation between rod and tibial axes never exceeded +/- 2 degrees. In the sagittal plane, the observed differences were larger. Significant differences between the considered axes appeared. The results of the two insertion techniques were not significantly different. Because an intramedullary rod frequently is used for alignment of the tibia in conventional surgery, these results also are valuable for conventional surgery. In the current study, the accuracy of the intramedullary alignment is examined, without influences of the sawing procedure. Moreover, the study is not limited to the frontal plane; the total accuracy in three-dimensional space, and the accuracy in the frontal and the sagittal planes were studied.