Wolfram Mittelmeier

A convenient approach for finite-element-analyses of orthopaedic implants in bone contact: Modeling and experimental validation

With regard to the growing potential of finite-element-analysis (FEA) in the field of orthopaedic biomechanics, we present an approach helping in the development of appropriate models of the implant-bone compound. The algorithm is based on computed-tomography data of the bone and accordant computer-aided-design (CAD) data of the implant and aims at predicting the bone strains and interface mechanics of the included parts. The developed algorithm was validated exemplary using an acetabular cup in combination with a left and a right fresh-frozen human hemipelvis. The strains under maximum loads during the gait cycle as well as the micromotion in the bone-implant interface were measured and compared to results from equivalent finite-element-analyses. Thereby, we found strong correlation between the calculated and measured principal strains with correlation coefficients of r(2)=0.94 (left side) and r(2)=0.86 (right side). A validation of micromotion was not possible due to limited accuracy of the motion tracking system.

Limited range of motion of hip resurfacing arthroplasty due to unfavorable ratio of prosthetic head size and femoral neck diameter

Background and purpose Hip resurfacing arthroplasty is being used more and more frequently. The small ratio in size between the resurfaced femoral head and the relatively thick femoral neck raises the question of whether the range of motion is sufficient, particularly with regard to the high mobility required by younger patients. We analyzed motion in a CAD model. Methods Three-dimensional CAD models of the natural hip were created from CT scans and 8 designs of hip resurfacing prostheses (head diameter between 42 mm and 54 mm combined with a hemispherical cup) were implanted in a virtual sense. We simulated 3 different leg positions and the range of motion was evaluated, considering five different implant positions. Results The range of motion of the hip resurfacing designs analyzed was far below the range of motion of stemmed total hip prostheses. None of the resurfacing prostheses provided flexion movements of 90° without impingement. The average range of motion of hip resurfacing arthroplasty was 31–48° below the range of motion of a stemmed total hip replacement with 32-mm head diameter. Interpretation The range of motion of the hip resurfacing designs examined was substantially less than that of a conventional total hip prosthesis. Since impingement of the femoral neck on the acetabular component increases the risk of neck fractures, of dislocation and of subsequent implant loosening, the design and position of the implant should be considered before using hip resurfacing arthroplasty as a standard treatment for younger patients.

Metal hypersensitivity in total knee arthroplasty: revision surgery using a ceramic femoral component - a case report.

We present a case involving the revision of a total knee arthroplasty with a metal femoral component using a ceramic implant due to metal hypersensitivity. A 58-year-old female patient underwent total knee arthroplasty (TKA) with a standard metal bicondylar knee system. She suffered from persistent pain and strong limitations in her range of motion (ROM) associated with flexion during the early postoperative period. Arthroscopic arthrolysis of the knee joint and intensive active and passive physical treatment, in combination with a cortisone regime, temporarily increased the ROM and reduced pain. No signs of low grade infection or other causes of implant failure were evident. Histology of synovial tissue revealed lymphoplasmacellular fibrinous tissue, consistent with a type IV allergic reaction. Allergometry (skin reaction) revealed type IV hypersensitivity against nickel-II-sulfate and palladium chloride. Revision surgery of the metal components was performed with a cemented ceramic femoral component (same bicondylar design) and a cemented titanium alloy tibial component. Postoperative evaluations were performed 10days, and 3 and 12months after the revision surgery. There was an increased ROM in flexion to 90° at the 12month follow-up. No swelling or effusion was observed at all clinical examinations after the revision surgery. No pain at rest and moderate walking pain were evident. The presented case demonstrates that ceramic implants are a promising solution for patients suffering from hypersensitivity to metal ions in total knee arthroplasty.

The influence of head and neck geometry on stability of total hip replacement: a mechanical test study.

Background Dislocation after replacement may be caused by poor implant design or positioning, or by the surgical approach taken. We evaluated the infl uence of head and neck design on range of motion and stability (with respect to risk of dislocation) in total hip endoprostheses. Material and methods Using a test device, we determined the stability afforded by different head sizes and neck geometries for various implant positions. Results Increasing head diameter led to an enhancement of range of motion as well as resistance against subluxation, and thus to improved stability in any movement combination and implant orientation. Smaller femoral heads were associated with increased risk of dislocation, especially in a poor implant position such as retroversion, and steep positioning of the cup. Skirted metal or mushroom-shaped ceramic heads had a reduced range of motion until impingement of approx. 20°, as compared to spherical standard heads. Furthermore, after identical joint loading, skirted heads dislocated more readily than standard heads with corresponding diameters. Interpretation To obtain sufficient joint mobility and stability, neck geometry and implant position should be considered when choosing the femoral head size.

An extended spectrum bactericidal titanium dioxide (TiO2) coating for metallic implants: in vitro effectiveness against MRSA and mechanical properties.

Implant infections remain feared and severe complications after total joint arthroplasty. The incidence of multi-resistant pathogens, causing such infections, is rising continuously, and orthopaedic surgeons are confronted with an ever-changing resistance pattern. Anti-infectious surface coatings aim for a high local effective concentration and a low systemic toxicity at the same time. Antibacterial efficacy and biomechanical stability of a novel broad-spectrum anti-infectious coating is assessed in the present study. Antibacterial efficacy of a sol–gel derived titanium dioxide (TiO2) coating for metal implants with and without integrated copper ions as antibiotic agent was assessed against methicillin resistant Staphylococcus aureus (MRSA 27065). Both bacterial surface adhesion and growth of planktonic bacteria were assessed with bare and various TiO2-coated Ti6Al4V metal discs. Furthermore, bonding strength of the TiO2 surface coating, using standard testing procedures, as well as surface roughness were determined. We found a significant reduction of the bacterial growth rate for the coatings with integrated copper ions, with highest reduction rates observed for a fourfold copper TiO2-coating. Pure TiO2 without integrated copper ions did not reduce bacterial growth compared to uncoated Ti6Al4V. The coating was not detached from the substrate by standard adhesive failure testing, which indicated an excellent durability of the implant coating. The TiO2 coating with integrated copper ions could offer a new strategy for preventing implant-associated infections, with antibacterial properties not only against the most common bacteria causing implant infections but also against multiresistant strains such as MRSA.

Finite Element Analysis of Osteosynthesis Screw Fixation in the Bone Stock: An Appropriate Method for Automatic Screw Modelling

The use of finite element analysis (FEA) has grown to a more and more important method in the field of biomedical engineering and biomechanics. Although increased computational performance allows new ways to generate more complex biomechanical models, in the area of orthopaedic surgery, solid modelling of screws and drill holes represent a limitation of their use for individual cases and an increase of computational costs. To cope with these requirements, different methods for numerical screw modelling have therefore been investigated to improve its application diversity. Exemplarily, fixation was performed for stabilization of a large segmental femoral bone defect by an osteosynthesis plate. Three different numerical modelling techniques for implant fixation were used in this study, i.e. without screw modelling, screws as solid elements as well as screws as structural elements. The latter one offers the possibility to implement automatically generated screws with variable geometry on arbitrary FE models. Structural screws were parametrically generated by a Python script for the automatic generation in the FE-software Abaqus/CAE on both a tetrahedral and a hexahedral meshed femur. Accuracy of the FE models was confirmed by experimental testing using a composite femur with a segmental defect and an identical osteosynthesis plate for primary stabilisation with titanium screws. Both deflection of the femoral head and the gap alteration were measured with an optical measuring system with an accuracy of approximately 3 µm. For both screw modelling techniques a sufficient correlation of approximately 95% between numerical and experimental analysis was found. Furthermore, using structural elements for screw modelling the computational time could be reduced by 85% using hexahedral elements instead of tetrahedral elements for femur meshing. The automatically generated screw modelling offers a realistic simulation of the osteosynthesis fixation with screws in the adjacent bone stock and can be used for further investigations.

Finite element analysis on the biomechanical stability of open porous titanium scaffolds for large segmental bone defects under physiological load conditions.

Repairing large segmental defects in long bones caused by fracture, tumour or infection is still a challenging problem in orthopaedic surgery. Artificial materials, i.e. titanium and its alloys performed well in clinical applications, are plenary available, and can be manufactured in a wide range of scaffold designs. Although the mechanical properties are determined, studies about the biomechanical behaviour under physiological loading conditions are rare. The goal of our numerical study was to determine the suitability of open-porous titanium scaffolds to act as bone scaffolds. Hence, the mechanical stability of fourteen different scaffold designs was characterized under both axial compression and biomechanical loading within a large segmental distal femoral defect of 30mm. This defect was stabilized with an osteosynthesis plate and physiological hip reaction forces as well as additional muscle forces were implemented to the femoral bone. Material properties of titanium scaffolds were evaluated from experimental testing. Scaffold porosity was varied between 64 and 80%. Furthermore, the amount of material was reduced up to 50%. Uniaxial compression testing revealed a structural modulus for the scaffolds between 3.5GPa and 19.1GPa depending on porosity and material consumption. The biomechanical testing showed defect gap alterations between 0.03mm and 0.22mm for the applied scaffolds and 0.09mm for the intact bone. Our results revealed that minimizing the amount of material of the inner core has a smaller influence than increasing the porosity when the scaffolds are loaded under biomechanical loading. Furthermore, an advanced scaffold design was found acting similar as the intact bone.

Response of human osteoblasts exposed to wear particles generated at the interface of total hip stems and bone cement

Aseptic loosening of total hip replacement is mainly caused by wear particles. Abrasive wear occurs at articulating surfaces or as a consequence of micro-motions at the interface between femoral stem and bone cement. Direct impact of wear particles on osteolysis, the remodeling of the bone stock and a directly affected function of osteoblasts was described. The present study examined the response of human osteoblasts exposed to different wear particles, which were generated in a test device providing oscillating micro-motions at the interface between femoral stem and standard bone cement. Characterization of released particles was performed by quantifying the size distribution and the metal content of the wear debris. Human osteoblasts were incubated with particles obtained from hip stems with different material compositions (Ti-6Al-7Nb and Co-28Cr-6Mo) and rough and smooth surface finishings combined with standard bone cement (Palacos(R) R) containing zirconium oxide particles. Commercially pure titanium particles (cp-Ti) and particulate zirconium oxide (ZrO(2)) were used for comparative analyses. The results revealed significant (p < 0.05) reduction of the cell viability after exposure to higher concentration of metallic particles, particularly from Co-based alloys. In contrast, ZrO(2) alone showed significantly less adverse effects on the cells. When increasing metallic particle concentrations massive inhibition was also observed in the release of cytokines including interleukine-6 (IL-6) and interleukine-8 (IL-8), but the expression of Procollagen I and the cell viability showed the highest reduction after exposure to Co-based alloy particles from rough stems.

Pitfalls in the use of acetabular reinforcement rings in total hip revision

Introduction: For the reconstruction of acetabular bone defects different types of acetabular reinforcement rings are being used. In clinical practice, these implants showed to some extent good long-term results. In the present work pitfalls and complications after the implantation of acetabular reinforcement rings as well as possible solutions are being discussed. Material and methods: In the first case recurrent dislocation was caused by the malposition of the acetabular component with an impingement of the protruding bone cement and the anterior edge of the acetabular ring as well as muscle insufficiency as a result of the shortening of the leg length. The second case revealed an impingement of the iliopsoas tendon due to a protruding acetabular reinforcement ring. During revision, bone cement was used to smoothen the protruding anterior edge of the acetabular reconstruction ring in order to obtain a relieved sliding of the tendon. Furthermore, we report on the case of a delayed neuropathy of the sciatic nerve after reconstruction of the acetabulum with an acetabular reinforcement ring. Results: Intraoperatively an impingement of the sciatic nerve at the protruding dorsal edge of the acetabular reinforcement ring and the surrounding scar tissue was found. In a further case an aseptic loosening of an acetabular reinforcement ring caused the formation of an excessive granuloma with a large intrapelvic portion. The granuloma led to persisting senso-motoric deficits of the femoral nerve. In summary, based on these clinical cases possible pitfalls, associated with the use of acetabular reinforcement rings, are shown. The mal-positioning and the intra-operative re-shaping of the implant by the surgeon are pointed out as the substantial factors for the occurrence of an impingement phenomenon and total hip instability. Furthermore, in case of an adequate orientation of the cemented polyethylene insert an improper position of the acetabular ring which results in protruding edges has to be considered as a cause of a prosthetic impingement. Conclusion: The cases presented emphasize the necessity of prevention of such pitfalls intra-operatively as well as accurate analysis of implant failures. Furthermore, they suggest explicit preoperative planning before deciding on the strategy of revision surgery of acetabular reinforcement rings.

Third-body abrasive wear of tibial polyethylene inserts combined with metallic and ceramic femoral components in a knee simulator study

Aim Total knee arthroplasties have reached a high grade of quality and safety, but most often fail because of aseptic implant loosening caused by polyethylene wear debris. Wear is generated at the articulating surfaces, e.g. caused by third-body particles. The objective of this experimental study was to determine the wear of tibial polyethylene inserts combined with metallic and ceramic femoral components under third-body wear conditions initiated by bone cement particles. Methods and Materials Wear testing using a cemented unconstrained bicondylar knee endoprosthesis (Multigen Plus CR knee system) was performed in a knee wear simulator. Tibial polyethylene inserts were combined with the identical femoral component design, but made of two different materials (cobalt-chromium and ceramic). Bone cement debris including zirconium oxide particles was added every 500,000 cycles between the articulating surfaces. After 5 million load cycles, the amount of wear was determined gravimetrically and compared with results from standard wear test conditions. The surfaces of tibial inserts were also analyzed. Results The average gravimetrical wear of the tibial polyethylene inserts in combination with cobalt-chromium and ceramic femoral components under third-body wear conditions amounted to 31.88 ± 4.53 mg and 13.06 ± 1.88 mg after 5 million cycles, respectively, and was higher than under standard wear test conditions in both cases. Conclusions The wear simulator test demonstrates that wear of polyethylene inserts under third-body wear conditions, in combination with ceramic femoral components, was significantly lower than with metallic femoral components.