Meghan Crookshank

Biomechanical Measurements of Surgical Drilling Force and Torque in Human Versus Artificial Femurs

Few experimental studies have examined surgical drilling in human bone, and no studies have inquired into this aspect for a popular commercially-available artificial bone used in biomechanical studies. Sixteen fresh-frozen human femurs and five artificial femurs were obtained. Cortical specimens were mounted into a clamping system equipped with a thrust force and torque transducer. Using a CNC machine, unicortical holes were drilled in each specimen at 1000 rpm, 1250 rpm, and 1500 rpm with a 3.2 mm diameter surgical drill bit. Feed rate was 120 mm/min. Statistical significance was set at p < 0.05. Force at increasing spindle speed (1000 rpm, 1250 rpm, and 1500 rpm), respectively, showed a range for human femurs (198.4 ± 14.2 N, 180.6 ± 14.0 N, and 176.3 ± 11.2 N) and artificial femurs (87.2 ± 19.3 N, 82.2 ± 11.2 N, and 75.7 ± 8.8 N). For human femurs, force at 1000 rpm was greater than at other speeds (p ≤ 0.018). For artificial femurs, there was no speed effect on force (p ≥ 0.991). Torque at increasing spindle speed (1000 rpm, 1250 rpm, and 1500 rpm), respectively, showed a range for human femurs (186.3 ± 16.9 N·mm, 157.8 ± 16.1 N·mm, and 140.2 ± 16.4 N·mm) and artificial femurs (67.2 ± 8.4 N·mm, 61.0 ± 2.9 N·mm, and 53.3 ± 2.9 N·mm). For human femurs, torque at 1000 rpm was greater than at other speeds (p < 0.001). For artificial femurs, there was no difference in torque for 1000 rpm versus higher speeds (p ≥ 0.228), and there was only a borderline difference between the higher speeds (p = 0.046). Concerning human versus artificial femurs, their behavior was different at every speed (force, p ≤ 0.001; torque, p < 0.001). For human specimens at 1500 rpm, force and torque were linearly correlated with standardized bone mineral density (sBMD) and the T-score used to clinically categorize bone quality (R ≥ 0.56), but there was poor correlation with age at all speeds (R ≤ 0.37). These artificial bones fail to replicate force and torque in human cortical bone during surgical drilling. To date, this is the largest series of human long bones biomechanically tested for surgical drilling.

Biomechanical measurements of cortical screw stripping torque in human versus artificial femurs

Femur fracture plates are applied using cortical bone screws. Surgeons do this manually by subjective ‘feel’ without monitoring torque. Few studies have quantified stripping torque in human bone. No studies have measured stripping torque in the artificial bones from Sawbones (Vashon, WA, USA) that are frequently used in biomechanical studies. The present aim was to measure stripping torque of cortical screws in human versus artificial femurs. Sixteen fresh-frozen human femurs and eight artificial femurs were used. Using a digital torque screwdriver, each femur had a 3.5-mm diameter unicortical screw manually inserted into the anterior midshaft until failure of the screw–bone interface. Results were normalized by cortical thickness and the screw–bone interfacial area. There were no statistical differences in human versus artificial data, respectively, for stripping torque (1741 ± 442 N.mm, 2012 ± 176 N.mm, p = 0.11), stripping torque/thickness (313 ± 59 N, 305 ± 30 N, p = 0.74), and stripping torque/area (28.5 ± 5.3 N/mm, 27.8 ± 2.8 N/mm, p = 0.74). Artificial unicortical thickness (6.6 ± 0.3 mm) was greater than human thickness (5.6 ± 1.1 mm) (p = 0.02). For human specimens, there was a moderate linear correlation of absolute and normalized stripping torque versus standardized bone mineral density (R ≥ 0.32) and clinical T-score (R = 0.29), but not with age (R ≤ 0.29). Surgeons should be aware of the stripping torque limits for human femurs and potentially take steps to monitor these values during surgery. The artificial femurs being increasingly used in research accurately replicate human cortical properties during screw insertion. To date, this is the first series of human femurs evaluated for cortical screw stripping.

Biomechanical measurements of axial crush injury to the distal condyles of human and synthetic femurs

Few studies have evaluated the ‘bulk’ mechanical properties of human longbones and even fewer have compared human tissue to the synthetic longbones increasingly being used by researchers. Distal femur fractures, for example, comprise about 6% of all femur fractures, but the mechanical properties of the distal condyles of intact human and synthetic femurs have not been well quantified in the literature. To this end, the distal portions of a series of 16 human fresh-frozen femurs and six synthetic femurs were prepared identically for mechanical testing. Using a flat metal plate, an axial ‘crush’ force was applied in-line with the long axis of the femurs. The two femur groups were statistically compared and values correlated to age, size, and bone quality. Results yielded the following: crush stiffness (human, 1545 ± 728 N/mm; synthetic, 3063 ± 1243 N/mm; p = 0.002); crush strength (human, 10.3 ± 3.1 kN; synthetic, 12.9 ± 1.7 kN; p = 0.074); crush displacement (human, 6.1 ± 1.8 mm; synthetic, 2.8 ± 0.3 mm; p = 0.000); and crush energy (human, 34.8 ± 15.9 J; synthetic, 18.1 ± 5.7 J; p = 0.023). For the human femurs, there were poor correlations between mechanical properties versus age, size, and bone quality (R2 ≤ 0.18), with the exception of crush strength versus bone mineral density (R2 = 0.33) and T-score (R2 = 0.25). Human femurs failed mostly by condyle ‘roll back’ buckling (15 of 16 cases) and/or unicondylar or bicondylar fracture (7 of 16 cases), while synthetic femurs all failed by wedging apart of the condyles resulting in either fully or partially displaced condylar fractures (6 of 6 cases). These findings have practical implications on the use of a flat plate load applicator to reproduce real-life clinical failure modes of human femurs and the appropriate use of synthetic femurs. To the authors’ knowledge, this is the first study to have done such an assessment on human and synthetic femurs.

Biomechanical measurements of stopping and stripping torques during screw insertion in five types of human and artificial humeri

During orthopedic surgery, screws are inserted by “subjective feel” in humeri for fracture fixation, that is, stopping torque, while trying to prevent accidental over-tightening that causes screw–bone interface failure, that is, stripping torque. However, no studies exist on stopping torque, stripping torque, or stopping/stripping torque ratio in human or artificial humeri. This study evaluated five types of humeri, namely, human fresh-frozen (n = 19), human embalmed (n = 18), human dried (n = 15), artificial “normal” (n = 13), and artificial “osteoporotic” (n = 13). An orthopedic surgeon used a torque screwdriver to insert 3.5-mm-diameter cortical screws into humeral shafts and 6.5-mm-diameter cancellous screws into humeral heads by “subjective feel” to obtain stopping and stripping torques. The five outcome measures were raw and normalized stopping torque, raw and normalized stripping torque, and stopping/stripping torque ratio. Normalization was done as raw torque/screw–bone interface area. For “gold standard” fresh-frozen humeri, cortical screw tests yielded averages of 1312 N mm (raw stopping torque), 30.4 N/mm (normalized stopping torque), 1721 N mm (raw stripping torque), 39.0 N/mm (normalized stripping torque), and 82% (stopping/stripping torque ratio). Similarly, fresh-frozen humeri gave cancellous screw average results of 307 N mm (raw stopping torque), 0.9 N/mm (normalized stopping torque), 392 N mm (raw stripping torque), 1.2 N/mm (normalized stripping torque), and 79% (stopping/stripping torque ratio). Of the five cortical screw parameters for fresh-frozen humeri versus other groups, statistical equivalence (p ≥ 0.05) occurred in four cases (embalmed), three cases (dried), four cases (artificial “normal”), and four cases (artificial “osteoporotic”). Of the five cancellous screw parameters for fresh-frozen humeri versus other groups, statistical equivalence (p ≥ 0.05) occurred in five cases (embalmed), one case (dried), one case (artificial “normal”), and zero cases (artificial “osteoporotic”). Stopping/stripping torque ratios were relatively constant for all groups at 77%–88% (cortical screws) and 79%–92% (cancellous screws).

3D atlas-based registration can calculate malalignment of femoral shaft fractures in six degrees of freedom

Abstract Objective: This study presents and evaluates a semi-automated algorithm for quantifying malalignment in complex femoral shaft fractures from a single intraoperative cone-beam CT (CBCT) image of the fractured limb. Methods: CBCT images were acquired of complex comminuted diaphyseal fractures created in 9 cadaveric femora (27 cases). Scans were segmented using intensity-based thresholding, yielding image stacks of the proximal, distal and comminuted bone. Semi-deformable and rigid affine registrations to an intact femur atlas (synthetic or cadaveric-based) were performed to transform the distal fragment to its neutral alignment. Leg length was calculated from the volume of bone within the comminution fragment. The transformations were compared to the physical input malalignments. Results: Using the synthetic atlas, translations were within 1.71 ± 1.08 mm (medial/lateral) and 2.24 ± 2.11 mm (anterior/posterior). The varus/valgus, flexion/extension and periaxial rotation errors were 3.45 ± 2.6°, 1.86 ± 1.5° and 3.4 ± 2.0°, respectively. The cadaveric-based atlas yielded similar results in medial/lateral and anterior/posterior translation (1.73 ± 1.28 mm and 2.15 ± 2.13 mm, respectively). Varus/valgus, flexion/extension and periaxial rotation errors were 2.3 ± 1.3°, 2.0 ± 1.6° and 3.4 ± 2.0°, respectively. Leg length errors were 1.41 ± 1.01 mm (synthetic) and 1.26 ± 0.94 mm (cadaveric). The cadaveric model demonstrated a small improvement in flexion/extension and the synthetic atlas performed slightly faster (6 min 24 s ± 50 s versus 8 min 42 s ± 2 min 25 s). Conclusions: This atlas-based algorithm quantified malalignment in complex femoral shaft fractures within clinical tolerances from a single CBCT image of the fractured limb.