Gordon W. Blunn

Attachment and proliferation of osteoblasts and fibroblasts on biomaterials for orthopaedic use

Using a variety of cell types, cell attachment and growth was studied on prospective (polyethersulphone (PES) and polyetheretherketone) and currently used (titanium 318 alloy, cobalt chrome molybdenum alloy and ultra-high molecular weight polyethylene (UHMWPE)) orthopaedic biomaterials. Proliferation of fibroblasts and osteoblasts was measured using incorporation of tritiated thymidine into total DNA. Attachment of cells was assessed by indirect immunofluorescent labelling of vinculin, a component of the cells focal adhesion plaque. The degree of cell attachment was quantified on the materials by determining the mean number of adhesion plaques and using an image analysis system to determine the mean total area of plaques per cell. Fibroblasts and osteoblasts responded differently to the materials tested. When grown on PES surfaces, rat tail fibroblasts synthesized significantly greater amounts of DNA than cells on all other surfaces, whilst fibroblasts on UHMWPE synthesized significantly less DNA than cells on all other materials. Interestingly, there was no significant difference between the amounts of DNA synthesized by osteoblasts grown on the various materials. Determination of the number of vinculin adhesion plaques per cell and the mean total area of the plaques per cell showed that the attachment of fibroblasts to UHMWPE was significantly reduced compared with other materials. In contrast there was no significant difference in the adhesion of osteoblasts to different materials. Scanning electron microscope (SEM) observations of cells on the materials correlated with the morphometric data. Cells with the greatest number and area of adhesion plaques were well spread and flattened whilst those with the least number of adhesion plaques were more rounded and less spread.

Wear in retrieved condylar knee arthroplasties

The plastic components of 280 retrieved unicondylar and total knee arthroplasties were studied. Wear was visually scored using a relative ranked data method. Although wear on the components was highly variable, several conclusions could be drawn regarding the nature and causes. Wear was associated more with the medial than the lateral condyle. Delamination was the most severe type of wear and occurred in short (< 5 year)-, medium (5-10 years)-, and long (> 10 years)-term retrievals. In the short term, delamination wear was associated with hot pressing of the tibial plastic or with fracture of the tibial baseplate. For a single design, a significant difference in the amount of delamination on hot-pressed and non-hot-pressed tibial components was observed. In medium- and long-term retrieved specimens of the designs with moderately high conformity, delamination wear was associated with restriction of rotational movement of the femoral component or with abrupt changes in the radius of the tibial component. In flatter, less conforming designs, wear was associated with laxity, such that the polyethylene delaminated toward the edges of the tibial component. Wear attributed to cement abrasion or entrapment occurred on the more conforming designs. Delamination was associated with the presence of fusion defects in the polyethylene but could also occur in the absence of such defects. That delamination was the principal were type and that this is caused by a fatigue mechanism mean that the incidence of failure could accelerate considerably over follow-up periods beyond 10 years. Designs of moderate conformity without abrupt changes in radii may prolong the duration of plastic tibial components before serious delamination occurs.

A knee simulating machine for performance evaluation of total knee replacements

A knee simulating machine is required for the design and evaluation of total knee replacements, the kinematics and the long-term wear being aspects of particular importance. There are no generally agreed design criteria, such that existing designs of simulator have a wide variety of input and constraint conditions. In this study, it was postulated that in order to reproduce physiological wear patterns, the correct kinematics is required, on the basis that the wear will be a direct function of the sliding, rolling and tractive rolling conditions at the joint surfaces. In turn, the correct kinematics would only be achieved by the input of physiological forces, by the appropriate constraints on the fixtures holding the components, and by simulating the soft tissue restraints. A knee simulating machine based on these principles was constructed, and used to test the kinematics of a range of contemporary condylar replacement knees. The displacements and rotations varied over a range of almost two times, even with the soft tissue restraints. Without the restraints, the low constraint designs would have dislocated or moved unrealistically. It was concluded that a simulating machine should be based on the input of forces and moments, rather than on displacements and rotations, in order to provide data of kinematics and wear.

Wear testing of materials and surfaces for total knee replacement.

A simple wear test was investigated for evaluating the wear and damage of material pairs when used in total knee replacement. The test consisted of an axially loaded metallic femoral indentor and a reciprocating ultrahigh molecular weight polyethylene (UHMWPE) flat disk that represented the tibial component. A number of variables were studied including the effect of conformity by varying the radii of the femoral surface, distilled water or serum as a lubricant, different femoral materials, and different types of UHMWPE. In general, the different morphologies of the surface wear of the UHMWPE were similar to those seen on retrieved total knee replacements. Increased conformity with a cylindrical indentor gave a reduced wear rate initially, compared with that of the lower conformity spherical indentor. However, the wear rates were similar subsequent to this initial wearing in phase. Transfer films of UHMWPE were observed on the cobalt-chrome indentors for both serum and distilled water lubrication, although this film was more extensive for distilled water. The lowest wear rate was observed when oxidized zirconium was used on the femoral side, which was attributed to greater wettability, surface hardness, and immunity to oxidative wear. Tests using cobalt-chrome femoral cylinders and different grades of UHMWPE showed different wear rates. Of these PEs, GUR 415 showed less wear than both RCH 1000 and UHMWPE containing numerous fusion defects. For the latter, wear was attributed to a fatigue mechanism, although in most cases it was associated with surface phenomena rather than subsurface cracking. However, in some specimens of UHMWPE subsurface crack propagations occurred with defects. The test method is discussed in relation to its applicability to the evaluation and comparison of bearing materials and surfaces, with particular application to total knee replacements.

A comparison of bone remodelling around hydroxyapatite-coated, porous-coated and grit-blasted hip replacements retrieved at post-mortem

We investigated the implant-bone interface around one design of femoral stem, proximally coated with either a plasma-sprayed porous coating (plain porous) or a hydroxyapatite porous coating (porous HA), or which had been grit-blasted (Interlok). Of 165 patients implanted with a Bimetric hip hemiarthroplasty (Biomet, Bridgend, UK) specimens were retrieved from 58 at post-mortem. We estimated ingrowth and attachment of bone to the surface of the implant in 21 of these, eight plain porous, seven porous HA and six Interlok, using image analysis and light morphometric techniques. The amount of HA coating was also quantified. There was significantly more ingrowth (p = 0.012) and attachment of bone (p < 0.05) to the porous HA surface (mean bone ingrowth 29.093 +/- 2.019%; mean bone attachment 37.287 +/- 2.489%) than to the plain porous surface (mean bone ingrowth 21.762 +/- 2.068%; mean bone attachment 18.9411 +/- 1.971%). There was no significant difference in attachment between the plain porous and Interlok surfaces. Bone grew more evenly over the surface of the HA coating whereas on the porous surface, bone ingrowth and attachment occurred more on the distal and medial parts of the coated surface. No significant differences in the volume of HA were found with the passage of time. This study shows that HA coating increases the amount of ingrowth and attachment of bone and leads to a more even distribution of bone over the surface of the implant. This may have implications in reducing stress shielding and limiting osteolysis induced by wear particles.

Material Loss at the Taper Junction of Retrieved Large Head Metal-on-Metal Total Hip Replacements

It has been speculated that material loss, either as corrosion or wear, at the head–stem taper junction is implicated in the high revision rates reported for metal‐on‐metal total hip replacements. We measured the volume of material loss from the taper and bearing surfaces of retrieved devices, and investigated the associations with blood metal ion levels and the diagnosis of a cystic or solid pseudotumor. The median volumes of material lost from the female and male taper surfaces were 2.0 and 0.29 mm3, respectively, while the median volumes of wear from the cup and head bearing surfaces were 1.94 and 3.44 mm3, respectively. Material loss from the female taper was similar to that from the acetabular bearing surface (p = 0.55), but significantly less than that from the femoral bearing surface (p < 0.001). Material loss from the male taper was less than that from both bearing surfaces (p < 0.001). Multivariable analysis demonstrated no significant correlations between the volume of material lost from the taper surfaces and either blood cobalt or chromium ions, or the presence of pseudotumor. While a substantial volume of material is lost at the taper junction, the clinical significance of this debris remains unclear.

Non-invasive distal femoral expandable endoprosthesis for limb-salvage surgery in paediatric tumours

We report our early experience with the use of a non-invasive distal femoral expandable endoprosthesis in seven skeletally immature patients with osteosarcoma of the distal femur. The patients had a mean age of 12.1 years (9 to 15) at the time of surgery. The prosthesis was lengthened at appropriate intervals in outpatient clinics, without anaesthesia, using the principle of electromagnetic induction. The patients were functionally evaluated using the Musculoskeletal Tumour Society scoring system. The mean follow-up was 20.2 months (14 to 30). The prostheses were lengthened by a mean of 25 mm (4.25 to 55) and maintained a mean knee flexion of 110 degrees (100 degrees to 120 degrees ). The mean Musculoskeletal Tumour Society score was 68% (11 to 29). Complications developed in two patients; one developed a flexion deformity of 25 degrees at the knee joint, which was subsequently overcome and one died of disseminated disease. The early results from patients treated with this device have been encouraging. The implant avoids multiple surgical procedures, general anaesthesia and assists in maintaining leg-length equality.

Metal ion levels after metal-on-metal proximal femoral replacements: A 30-YEAR FOLLOW-UP

Metal-on-metal hip bearings are being implanted into younger patients. The consequence of elevated levels of potentially carcinogenic metal ions is therefore a cause for concern. We have determined the levels of cobalt (Co), chromium (Cr), titanium (Ti) and vanadium (Va) in the urine and whole blood of patients who had had metal-on-metal and metal-on-polyethylene articulations in situ for more than 30 years. We compared these with each other and with the levels for a control group of subjects. We found significantly elevated levels of whole blood Ti, Va and urinary Cr in all arthroplasty groups. The whole blood and urine levels of Co were grossly elevated, by a factor of 50 and 300 times respectively in patients with loose metal-on-metal articulations when compared with the control group. Stable metal-on-metal articulations showed much lower levels. Elevated levels of whole blood or urinary Co may be useful in identifying metal-on-metal articulations which are loose.

Effect of oxidation on delamination of ultrahigh-molecular-weight polyethylene tibial components

Whether oxidation of ultrahigh-molecular-weight polyethylene (UHMWPE) causes delamination of the plastic in total knee arthroplasties (TKAs) was investigated. Examination of retrieved TKAs has shown that oxidation of UHMWPE can be caused by postirradiation damage leading to a subsurface band or, to a lesser extent, by mechanical forces during use leading to surface oxidation. Delamination cracks propagated through the subsurface oxidized band. In wear tests, delamination occurred in artificially aged UHMWPE where only subsurface oxidized bands had formed. Increased surface wear predominated where oxidation was associated with the surface of the plastic. Similarly, in tensile and fatigue tests of oxidized UHMWPE, there was a significant reduction in the ultimate tensile strength and in the fatigue resistance of specimens that had developed a subsurface band. Oxidation increased fatigue crack growth rate. It was observed that UHMWPE from different manufacturers varied in its resistance to oxidation. This study demonstrates that the effect of oxidation, which results in the development of a subsurface white band, combined with high subsurface shear forces observed in TKAs, is to enhance delamination wear.

Methodology for long-term wear testing of total knee replacements.

This article begins to address the validation requirements of wear testing on total knee replacements in a knee simulator. The knee simulator has four stations. The axial force is variable but reaches a maximum of 2.3 kN. Physiologic anteroposterior shear force and rotational torques are supplied to the knee. The forces and displacements are timed to coincide with those of a typical gait cycle. Kinematics of the simulator are dependent on the type of knee being tested. Tests of designs with well known clinical histories were done to 10 million cycles. The relative amounts and types of wear shown by the designs were similar to that found in their clinical histories. Wear tracks on more conforming designs were larger, and the penetration into the plastic appeared to be less. This did not necessarily mean that wear, as measured by loss of material, was reduced on conforming designs. Delamination of the plastic was achieved only after aging the tibial components. Wear particles isolated from the lubricating fluid were similar in size and shape to those isolated from in vivo specimens. However, the relative amounts of wear particle shapes were different depending on the design. At the start of the tests, all of the flexibly mounted tibial components showed more motion than after 5 million cycles, indicating that the surface of the plastic became more conforming. This study showed that knee wear similar to wear observed in vivo can be reproduced in the laboratory. The parameters and methods elucidated in this introductory study should form the basis for use in preclinical wear tests of total knee replacements.