Modified PMMA cements for a hydrolysis resistant metal-polymer interface in orthopaedic applications

Evaluation of the Effect of Selected Physiological Fluid Contaminants on the Mechanical Properties of Selected Medium-Viscosity PMMA Bone Cements

Revision surgeries several years after the implantation of the prosthesis are unfavorable from the patient’s point of view as they expose him to additional discomfort, to risk of complications and are expensive. One of the factors responsible for the aseptic loosening of the prosthesis is the gradual degradation of the cement material as a result of working under considerable loads, in an aggressive environment of the human body. Contaminants present in the surgical field may significantly affect the durability of the bone cement and, consequently, of the entire bone-cement-prosthesis system. The paper presents the results of an analysis of selected mechanical properties of two medium-viscosity bone cements DePuy CMW3 Gentamicin and Heraeus Palamed, for the samples contaminated with saline and blood in the range of 1–10%. The results obtained for compressive strength and modulus of elasticity were subjected to statistical analysis, which estimated the nature of changes in these parameters depending on the amount and type of contamination and their statistical significance.

Effect of Physiological Fluids Contamination on Selected Mechanical Properties of Acrylate Bone Cement

This study analyses the degradation rate of selected mechanical properties of bone cement contaminated with human blood and saline solution. During the polymerisation stage, the PMMA cement specimens were supplemented with the selected physiological fluids in a range of concentrations from 0% to 10%. The samples were then subjected to the standardised compression tests, as per ISO 5833: 2002, and hardness tests. The obtained results were analysed statistically to display the difference in the degradation of the material relative to the degree of contamination. Subsequently, numerical modelling was employed to determine the mathematical relationship between the degree of contamination and the material strength degradation rate. The introduction of various concentrations of contaminants into the cement mass resulted in a statistically significant change in their compressive strength. It was shown that the addition of more than 4% of saline and more than 6% of blood (by weight) causes that the specimens exhibit lower strength than the minimum critical value of 70 MPa, specified in the abovementioned International Standard. It was further revealed that the cement hardness characteristics degraded accordingly. The mathematical models showed a very good fit with the results from the experiments: The coefficient of determination R2 was 0.987 in the case of the linear hardness model for blood and 0.983 for salt solution; secondly, the values of R2 for the third-degree polynomial model of compressive strength were 0.88 for blood and 0.92 for salt. From the results, it can be seen that there is a quantitative/qualitative relationship between the contamination rate and the drop in the tested mechanical characteristics. Therefore, great effort must be taken to minimise the contact of the bone cement with physiological fluids, which naturally occur in the operative field, particularly when the material cures, in order to prevent the cement material strength declining below the minimum threshold specified in the ISO standard.

Seasoning Polymethyl Methacrylate (PMMA) Bone Cements with Incorrect Mix Ratio

Cemented joint prostheses are widely used in orthopaedic surgery; however, implants/bone bonds are known to be susceptible to aseptic loosening, particularly in the case of long-term performance. The exact mechanism of this failure is under constant examination. One of the critical factors to the final mechanical functionality of bone cement can be an incorrect mix ratio of a two-component material (powdered polymer and liquid monomer). It can result in the deterioration of the final mechanical strength properties. The paper presents the results from an experimental study on the effects of the deviation from the correct mix ratio on the moisture uptake and the compression strength of cement depending on the seasoning time in Ringer's solution. The results were subjected to statistical analysis and a mathematical model was developed.

Bio-inspired and optimized interlocking features for strengthening metal/polymer interfaces in additively manufactured prostheses

Biomedical and dental prostheses combining polymers with metals often suffer failure at the interface. The weak chemical bond between these two dissimilar materials can cause debonding and mechanical failure. This manuscript introduces a new mechanical interlocking technique to strengthen metal/polymer interfaces through optimized additively manufactured features on the metal surface. To reach an optimized design of interlocking features, we started with the bio-mimetic stress-induced material transformation (SMT) optimization method. The considered polymer and metal materials were cold-cured Poly(methyl methacrylate) (PMMA) and laser-sintered Cobalt-Chromium (Co-Cr), respectively. Optimal dimensions of the bio-inspired interlocking features were then determined by mesh adaptive direct search (MADS) algorithm combined with finite element analysis (FEA) and tensile experiments such that they provide the maximum interfacial tensile strength and stiffness while minimizing the stress in PMMA and the displacement of PMMA at the Co-Cr/PMMA interface. The SMT optimization process suggested a Y-shape as a more favorable design, which was similar to mangrove tree roots. Experiments confirmed that our optimized interlocking features increased the strength of the Co-Cr/PMMA interface from 2.3 MPa (flat interface) to 34.4 ± 1 MPa, which constitutes 85% of the tensile failure strength of PMMA (40.2 ± 1 MPa). STATEMENT OF SIGNIFICANCE: The objective of this study was to improve metal/polymer interfacial strength in dental and orthopedic prostheses. This was achieved by additive manufacturing of optimized interlocking features on metallic surfaces using laser-sintering. The interlocking design of the features, which was a Y-shape similar to the roots of mangrove trees, was inspired by a bio-memetic optimization algorithm. This interlocking design lowered the PMMA displacement at the Co-Cr/PMMA interface by 70%, enhanced the interfacial strength by more than 12%, and increased the stiffness by 18% compared with a conventional bead design, meanwhile no significant difference was found in the toughness of both designs.

Microgroove and Collagen-poly(ε-caprolactone) Nanofiber Mesh Coating Improves the Mechanical Stability and Osseointegration of Titanium Implants

The effect of depositing a collagen (CG)-poly-ε-caprolactone (PCL) nanofiber mesh (NFM) at the microgrooves of titanium (Ti) on the mechanical stability and osseointegration of the implant with bone was investigated using a rabbit model. Three groups of Ti samples were produced: control Ti samples where there were no microgrooves or CG-PCL NFM, groove Ti samples where microgrooves were machined on the circumference of Ti, and groove-NFM Ti samples where CG-PCL NFM was deposited on the machined microgrooves. Each group of Ti samples was implanted in the rabbit femurs for eight weeks. The mechanical stability of the Ti/bone samples were quantified by shear strength from a pullout tension test. Implant osseointegration was evaluated by a histomorphometric analysis of the percentage of bone and connective tissue contact with the implant surface. The bone density around the Ti was measured by micro–computed tomography (μCT) analysis. This study found that the shear strength of groove-NFM Ti/bone samples was significantly higher compared to control and groove Ti/bone samples (p < 0.05) and NFM coating influenced the bone density around Ti samples. In vivo histomorphometric analyses show that bone growth into the Ti surface increased by filling the microgrooves with CG-PCL NFM. The study concludes that a microgroove assisted CG-PCL NFM coating may benefit orthopedic implants.

Ageing and moisture uptake in polymethyl methacrylate (PMMA) bone cements

Bone cements are extensively employed in orthopaedics for joint arthroplasty, however implant failure in the form of aseptic loosening is known to occur after long-term use. The exact mechanism causing this is not well understood, however it is thought to arise from a combination of fatigue and chemical degradation resulting from the hostile in vivo environment. In this study, two commercial bone cements were aged in an isotonic fluid at physiological temperatures and changes in moisture uptake, microstructure and mechanical and fatigue properties were studied. Initial penetration of water into the cement followed Fickian diffusion and was thought to be caused by vacancies created by leaching monomer. An increase in weight of approximately 2% was experienced after 30 days ageing and was accompanied by hydrolysis of poly(methyl methacrylate) (PMMA) in the outermost layers of the cement. This molecular change and the plasticising effect of water resulted in reduced mechanical and fatigue properties over time. Cement ageing is therefore thought to be a key contributor in the long-term failure of cemented joint replacements. The results from this study have highlighted the need to develop cements capable of withstanding long-term degradation and for more accurate test methods, which fully account for physiological ageing.

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Two commercial bone cements were aged in Ringer's solution at 37 °C for 60 days.

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Moisture uptake, mechanical, fatigue and microstructural properties were studied.

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A maximum of 2% change in weight occurred due to Fickian diffusion after 30 days.

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Hydrolysis of PMMA and reduced mechanical and fatigue properties were observed.

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Cement degradation is thought to contribute to the failure of cemented implants.

Mussel-inspired load bearing metal-polymer glues

A mussel-inspired synthetic adhesive based on dopamine containing methacrylate copolymers was developed to bond polymers to metal surfaces at an adhesion strength of up to 20 MPa for bulk samples.

Viscoelastic and biological performance of low-modulus, reactive calcium phosphate-filled, degradable, polymeric bone adhesives

The aim of this study was to investigate the effect of reactive mono- and tricalcium phosphate addition on the mechanical, surface free energy, degradation and cell compatibility properties of poly(lactide-co-propylene glycol-co-lactide) dimethacrylate (PPGLDMA) thin films. Dry composites containing up to 70 wt.% filler were in a flexible rubber state at body temperature. Filler addition increased the initial strength and Young’s modulus and reduced the elastic and permanent deformation under load. The polymer had high polar surface free energy, which might enable greater spread upon bone. This was significantly reduced by filler addition but not by water immersion for 7 days. The samples exhibited reduced water sorption and associated bulk degradation when compared with previous work with thicker samples. Their cell compatibility was also improved. Filler raised water sorption and degradation but improved cell proliferation. The materials are promising bone adhesive candidates for low-load-bearing areas.

Mechanical properties and drug release behavior of bioactivated PMMA cements

Septic loosening of cemented implants represents an unresolved long-term problem of total hip endoprostheses. Common treatments of infected prostheses involve the use of temporary antibiotic-loaded PMMA spacer-implants or antibiotic-loaded cements. The latter are either provided by a manufacturer or are obtained by simply mixing specific antibiotic powders according to a microbial sensitivity test with PMMA cement. This study is aimed to investigate the antibiotic release behavior and mechanical properties of novel modified PMMA cements, which were bioactivated by chemical modification of commercial cements with either 0.5% hydroxyethylmethacrylate-phosphate (HEMA-P) or 0.5% hydroxyethylmethacrylate-phosphate + calcium chloride and sodium carbonate as buffer. Tobramycin release experiments from the cements were performed statically by immersion of the drug-loaded samples in PBS buffer following liquid change after different periods of time or during cyclic mechanical loading of the cement samples. Cement modification did not significantly alter the mechanical properties of the cements, but affected the release rate from the matrix. While the unmodified cement released approximately 0.33 mg/cm(2) tobramycin after 48 h independent of the testing regime, modification with both HEMA-P and salt buffer increased the antibiotic release to 37-50 mg/cm(2) when tested under cyclical mechanical loading.

Bone cements and their potential use in a mandibular endoprosthesis

Bone cement was first used in the 1950s. Since then many modifications have been made and alternatives developed to the original polymethylmethacrylate (PMMA) cement. In view of the use of bone cement in a novel mandibular endoprosthetic system, we performed a review of the current literature on this material. Different cements are described and their potential use in a mandibular endoprosthetic system discussed. The PMMA-based cements are currently the most suitable choice. Plain PMMA has the longest track record and is the default choice for the initial development phase of this system. If there is a significant risk of infection, then an antibiotic-loaded PMMA cement can be selected. However, modified PMMA cements, composite resin cements, osteoinductive calcium phosphate compounds, and cementless fixation are options that offer advantages over PMMA cements, and further research should be conducted to study their suitability.

Composite fibrous biomaterials for tissue engineering obtained using a supercritical CO2 antisolvent process

Several techniques have been proposed for producing porous structures or scaffolds for tissue engineering but, as yet, with no optimal solution. With regard to this topic, this paper focuses on the preparation of biocompatible nanometric filler-polymer composites organized in a network of fibers. Titanium dioxide (TiO2) or hydroxyapatite (HAP) nanopowders as the guest particles and poly(lactic acid) (L-PLA) or the blend poly(methylmethacrylate)/poly(epsilon-caprolactone) (PMMA/PCL) as the polymer carrier were selected as model systems for this purpose. A supercritical antisolvent technique was used to produce the composites. In the process developed, the non-soluble particulate filler was suspended in a polymer solution, and both components were sprayed simultaneously into supercritical carbon dioxide (scCO2). Using this technique, polymeric matrices were loaded with approximately 10-20 wt.% of inorganic phase distributed throughout the composite. Two different hybrid materials were prepared: a PMMA/PCL+TiO2 system where either fibers or microparticles were prepared by varying the molecular weight of the used PMMA; and fibers in the case of L-PLA+HAP system. After further post-processing in a three-dimensional network, these nanofibers can potentially be used as scaffolds for tissue engineering.

Alternative acrylic bone cement formulations for cemented arthroplasties: present status, key issues, and future prospects

All the commercially available plain acrylic bone cement brands that are used in cemented arthroplasties are based on poly (methyl methacrylate) and, with a few exceptions, have the same constituents. It is well known that these brands are beset with many drawbacks, such as high maximum exotherm temperature, lack of bioactivity, and volumetric shrinkage upon curing. Furthermore, concerns have been raised about a number of the constituents, such as toxicity of the activator (N,N,dimethyl-p-toluidine) and possible involvement of the radiopacifier (BaSO(4) or ZrO(2) particles) in third-body wear. Thus, over the years, many research efforts have been expended to address these drawbacks, culminating in a large number of alternative formulations, which may be grouped into 16 categories. Although there are a number of reviews of the large literature that now exists on these formulations, each covers only some of the categories and none contains a detailed discussion of the germane issues. The objective of the present work, therefore, was to present a comprehensive and critical review of the whole field. In addition to succinct descriptions of the cements in each category, there are explicative summaries of literature reports, a detailed discussion of several key issues surrounding the potential for use of these cements in cemented arthroplasties, and a presentation of numerous ideas for future studies.

Correlation between heparin release and polymerization degree of organically modified silica xerogels from 3-methacryloxypropylpolysilsesquioxane

This work aimed to investigate the use of an organically modified porous silica matrix (poly(methacryloxypropyl)-poly(silsesquioxane); P-MA-PS) as a release system for heparin. The matrices were obtained from methacryloxypropyltrimethoxysilane (MAS) via the sol-gel process under acidic conditions following photochemical polymerization and cross-linking of the organic matrix. Modulation of the polymerization degree of the organic matrix in the range 0-71% allowed adjusting the release kinetics of heparin according to therapeutic needs. It was demonstrated that higher drug loads and a decreasing polymerization degree resulted in a faster release profile of heparin, which followed a square root of time kinetic according to the Higuchi model. The hydrolytic degradation of hybrid xerogel was found to follow a zero-order kinetic whereas the heparin concentration did not show an influence on the degradation rate of the matrix. Since the released heparin retained its biological activity, the P-MA-PS matrices are of clinically interest, e.g. as coating on drug eluting coronary stents.