Development and Validation of Patient-Specific Finite Element Models of the Hemipelvis Generated From a Sparse CT Data Set

To produce a patient-specific finite element (FE) model of a bone such as the pelvis, a complete computer tomographic (CT) or magnetic resonance imaging (MRI) geometric data set is desirable. However, most patient data are limited to a specific region of interest such as the acetabulum. We have overcome this problem by providing a hybrid method that is capable of generating accurate FE models from sparse patient data sets. In this paper, we have validated our technique with mechanical experiments. Three cadaveric embalmed pelves were strain gauged and used in mechanical experiments. FE models were generated from the CT scans of the pelves. Material properties for cancellous bone were obtained from the CT scans and assigned to the FE mesh using a spatially varying field embedded inside the mesh while other materials used in the model were obtained from the literature. Although our FE meshes have large elements, the spatially varying field allowed them to have location dependent inhomogeneous material properties. For each pelvis, five different FE meshes with a varying number of patient CT slices (8–12) were generated to determine how many patient CT slices are needed for good accuracy. All five mesh types showed good agreement between the model and experimental strains. Meshes generated with incomplete data sets showed very similar stress distributions to those obtained from the FE mesh generated with complete data sets. Our modeling approach provides an important step in advancing the application of FE models from the research environment to the clinical setting.

Nanosurfaces and nanostructures for artificial orthopedic implants

Nanomaterials and structures, such as nanoparticles, nanofibers, nanosurfaces, nanocoatings, nanoscaffolds and nanocomposites, are considered for various applications in orthopedics and traumatology. This review looks at proposed nanotechnology inspired applications for implants from the perspective of the orthopedic industry. Investigations support consistently the theory that most nanomaterials in various physical forms are able to enhance the cell response selectively for biological tissue integration or increase the strength and wear resistance of current orthopedic materials. At this stage, most of the studies are at the laboratory scale or in early in vivo testing. Significant basic and applied research and development is needed to realize their full clinical potential and biological, manufacturing, economic and regulatory issues have to be addressed. Nevertheless, a crucial factor for success is well-coordinated multimethod and multidiscipline teamwork with profound industrial and medical expertise.

The use of sparse CT datasets for auto-generating accurate FE models of the femur and pelvis

The finite element (FE) method when coupled with computed tomography (CT) is a powerful tool in orthopaedic biomechanics. However, substantial data is required for patient-specific modelling. Here we present a new method for generating a FE model with a minimum amount of patient data. Our method uses high order cubic Hermite basis functions for mesh generation and least-square fits the mesh to the dataset. We have tested our method on seven patient data sets obtained from CT assisted osteodensitometry of the proximal femur. Using only 12 CT slices we generated smooth and accurate meshes of the proximal femur with a geometric root mean square (RMS) error of less than 1 mm and peak errors less than 8 mm. To model the complex geometry of the pelvis we developed a hybrid method which supplements sparse patient data with data from the visible human data set. We tested this method on three patient data sets, generating FE meshes of the pelvis using only 10 CT slices with an overall RMS error less than 3 mm. Although we have peak errors about 12 mm in these meshes, they occur relatively far from the region of interest (the acetabulum) and will have minimal effects on the performance of the model. Considering that linear meshes usually require about 70-100 pelvic CT slices (in axial mode) to generate FE models, our method has brought a significant data reduction to the automatic mesh generation step. The method, that is fully automated except for a semi-automatic bone/tissue boundary extraction part, will bring the benefits of FE methods to the clinical environment with much reduced radiation risks and data requirement.

Severe wear and fracture of zirconia heads against alumina inserts in hip simulator studies with microseparation

The wear of zirconia femoral heads against alumina acetabular inserts with swing-phase microseparation was investigated in a hip joint simulator. Under mild microseparation conditions, the wear was very low, with an average wear rate of 0.05 mm(3)/million cycles reported over 5 million cycles of testing. However, under severe microseparation conditions representative of greater joint laxity, the wear rate of zirconia against alumina increased by 2 orders of magnitude, producing severe wear and, in one case, femoral head fracture. The adverse results of this study indicate that the combination of a zirconia femoral head articulating against an alumina acetabular insert is not recommended for clinical use. The results further raise concerns over the suitability of conventional simulators in evaluating the wear of ceramic hip prostheses.

Long-term wear of ceramic matrix composite materials for hip prostheses under severe swing phase microseparation

The purpose of this study was to evaluate the long-term wear performance of alumina matrix composite (AMC) heads against alumina matrix composite inserts and alumina matrix composite heads against alumina (Al) inserts with the use of a hip-joint simulator incorporating severe swing phase joint microseparation. The wear of AMC on Al produced an average wear rate of 0.61 mm3/million cycles over the 5-million-cycle test duration. The wear of AMC on AMC produced an average wear rate of 0.16 mm3/million cycles over the 5-million-cycle test duration. Both the AMC on alumina and AMC on AMC produced significantly lower wear than previously tested HIPed alumina, where an average wear rate of 1.84 mm3/million cycles was reported over 5 million cycles. The wear mechanisms and wear debris of AMC on AMC and AMC on Al were similar to those observed in previous alumina retrieval studies with stripe wear caused by intragranular fracture and wear debris consisting of predominantly uniform 10-20-nm-sized particles and a few irregular particles up to 3 microm in size.

[Polyethylene as an implant material]

Since the early 1960s, ultrahigh-molecular weight polyethylene (UHMWPE) has been one of the most frequently and successfully used materials in total joint replacement. However, in the course of clinical usage, various weaknesses of the material became apparent including wear and aging properties. As a result of research on this polymer, several improvements in the quality of the raw material, the processing, and the sterilization have been introduced. These changes paired with an improved knowledge of the viscoelastic behavior of UHMWPE have led to an improved design of the components to meet the requirements of the given material characteristics and in turn to better clinical results. In the 1990s, investigations focused on the influence of radiation on the molecular structures of polyethylene. Gamma radiation treatment in air leads to an important decrease in the molecular weight with reduced tribological behavior and accelerated aging. In contrast, a nitrogen atmosphere during irradiation and storage can improve the linkage of the polyethylene and promote the positive effects of radiation treatment. This effect can be further intensified by increased radiation levels. Such highly cross-linked polyethylenes demonstrate extremely low wear rates in vitro;however, other material properties are also changed. First reports on fissures in highly cross-linked polyethylene explants demonstrate that only long-term clinical trials can allow a final verdict on the clinical potential of highly cross-linked polyethylenes.

Metal-on-metal articulation for artificial hip joints: laboratory study and clinical results

As wear is inevitable with artificial joint replacement, it has to be minimized to avoid possible aseptic loosening following osteolysis due to particle-initiated foreign body reaction. Co-Cr-Mo-C alloys have a long history with only minimum wear when articulating with themselves. This investigation shows that the choice of the alloy has an effect on the wear rate of this articulation couple. Tribological studies in a screening device, a pendulum apparatus and a hip joint simulator showed a marked influence of the environment as well as the diameter of the implants with metal-on-metal articulation. A wear-resistant combination with low friction characteristics has been developed by using a wrought Co-Cr-Mo-C alloy and reducing the implant diameter to 28 mm. Clinical wear rates are comparable with laboratory data and demonstrate the potential of the metal-on-metal articulation to solve the problem of wear-induced osteolysis of hip joint endoprostheses.

[UHMW-polyethylene as the substance for articulating components of joint prostheses]

In recent years there has been an increase in the incidence of problems with UHMWPE used in implants. In particular the risk of osteolysis and loosening resulting from the body's reactions to polyethylene wear particles must be eliminated. A variety of investigations with UHMWPE provided hints on how to improve the quality of the original material, machining and reduction of contaminants, which have since been implemented. The knowledge gained of the visco-elastic behaviour of this polymer makes it possible to optimize the design of implant components. The need to sterilize the component parts with ionizing radiation results in changes in the structure of UHMWPE. Via oxidation and acceleration of the ageing process of the material, irradiation in air reduces the molecular weight, which is important for the tribological properties. The use of a nitrogen atmosphere during irradiation and for storage makes it possible to take advantage of the positive effects of this method of sterilization via cross-linking of the polyethylene. Positive ductile properties are thus maintained and the resistance to wear is increased. An investigation of 134 components explanted during re-operation revealed a wide scatter in the results of wear. One of the reasons for increased polyethylene wear is the additional abrasive effect of particles of bone cement that get into the space between the articulating components; this can be minimized by a meticulous cementing technique.

Total hip joint replacement using a CoCrMo metal-metal sliding pairing

Late loosening in total hip replacement is explained by a foreign body reaction of the connective tissue along the bone-implant interface due to polyethylene debris. In contrast, metal-metal prostheses of the McKee type implanted in the sixties, may still work perfectly today without any signs of osteolysis along the bone-cement interface, proving that metal-metal pairing is superior to prostheses with polyethylene cups and proving also that cement anchorage may be adequate for fixation. A new metal-metal total hip joint is presented, that has been implanted 90 times between 1988 and 1991.

[Exposure of surgical/orthopedic operating room personnel to monomer vapors during the use of bone cements--review of the literature and report of experiences]

PMMA bone cements are used for the fixation of artificial joint replacements. During their application in the operating theater, a small amount of the monomer evaporates. Operating room staff and surgeons are often not adequately informed about the negative properties and the effects on health of these vapours. Basic information about monomers and their toxicity, and safety regulations have been compiled. On the basis of present knowledge, the authors do not regard the repeated use of bone cement throughout the course of a day to represent a hazard to health.

Joint replacement components made of hot-forged and surface-treated Ti-6Al-7Nb alloy

We have developed a titanium-aluminium alloy with the inert alloying element niobium. The optimal composition was found to be Ti-6Al-7Nb (Protasul-100). This custom-made alloy designed for implants shows the same alpha/beta structure as Ti-6Al-4V and exhibits equally good mechanical properties. The corrosion resistance of Ti-6Al-7Nb in sodium chloride solution is equivalent to that of pure titanium and Ti-6Al-4V. This is due to a very dense and stable passive layer. Highly stressed anchorage stems of different hip prosthesis designs have been made from hot-forged Ti-6Al-7Nb. The polished surfaces of hip, knee and wrist joints made of Ti-6Al-7Nb and articulating against polyethylene are surface-treated by means of a very hard and 3-5 microns thick titanium nitride coating (Tribosul-TiN) or by oxygen diffusion hardening (Tribosul-ODH) to a depth of 30 microns.

Total Hip Joint Replacement Using a CoCrMo Metal-Metal-Sliding Pairing

Late loosening in total-hip replacement is explained by a foreign body reaction of the connective tissue along the bone-implant interface due to polyethylene debris. In contrast, metal-metal prostheses of the McKee type implanted in the sixties, may still work perfectly today without any signs of osteolysis along the bone-cement interface, providing that metal-metal pairing is superior to prostheses with polyethylene cups and providing also that cement anchorage may be adequate for fixation. A new metal-metal total hip joint is presented, that has been implanted 62 times between 1988 and 1990. Key words: total hip replacement, metal-metal pairing.

[Joint prostheses components of warm-forged and surface treated Ti-6Al-7Nb alloy]

In 1978 development of a TiAl alloy with the inert alloying element niobium was initiated. In 1984, the optimal composition was found to be Ti-6Al-7Nb (Protasul-100). This custom-made alloy for implants has the same alpha/beta micro-structure and equally good mechanical properties as Ti-6Al-4V. The corrosion resistance of Ti-6Al-7Nb is better than that of pure titanium and Ti-6Al-4V, due to the very dense and stable passive layer. Since 1985, highly stressed anchoring stems of various hip prosthesis designs have been manufactured from hot-forged Ti-6Al-7Nb/Protasul-100. Polished surfaces of hip, knee or wrist joints made of Ti-6Al-7Nb intended to articulate with polyethylene are surface-treated by the application of a very hard, 3-5 microns thick titanium nitride coating (Tribosul-TiN), or by oxygen diffusion hardening (Tribosul-ODH) to a depth of 30 microns.

New surface modification for Ti-6Al-7Nb alloy: oxygen diffusion hardening (ODH)

PVD-TiN coating and N+ implantation of Ti-6Al-7Nb alloy resulted in surface hardening to a depth of less 3 microns. The new oxygen diffusion hardening (ODH) treatment increased the hardness gradually to 50 microns. PUD-TiN showed an improvement in the tribological properties, while N+ implantation increased the PE wear rate. The wear rate of the ultrahigh-molecular-weight as well as the friction coefficient were reduced to one-half of the values achieved with the combination of CoCrMo-alloy when paired against the ODH-treated surface. In pairing with ZrO2-containing bone cement the ODH-treated surface showed only a minimal reaction.

[The wear behavior of capsules and heads of CoCrMo casts in long-term implanted all-metal hip prostheses]

We conducted an investigation on total hip prostheses with cups and balls made of cast CoCrMo alloy that were implanted 10-20 years ago; our results showed that this metal/metal alloy showed very low wear and tear. In comparison, the polyethylen/metal alloy showed a 40 times higher wear in the polyethylene part. Based on these promising long-term clinical results, the metal/metal alloy is again of great interest for total hip prostheses.