Towards optimization of volar plate fixations of distal radius fractures: Using finite element analyses to reduce the number of screws

Design considerations for patient-specific bone fixation plates: a literature review

In orthopedic surgery, patient-specific bone plates are used for fixation when conventional bone plates do not fit the specific anatomy of a patient. However, plate failure can occur due to a lack of properly established design parameters that support optimal biomechanical properties of the plate.This review provides an overview of design parameters and biomechanical properties of patient-specific bone plates, which can assist in the design of the optimal plate.A literature search was conducted through PubMed and Embase, resulting in the inclusion of 78 studies, comprising clinical studies using patient-specific bone plates for fracture fixation or experimental studies that evaluated biomechanical properties or design parameters of bone plates. Biomechanical properties of the plates, including elastic stiffness, yield strength, tensile strength, and Poisson's ratio are influenced by various factors, such as material properties, geometry, interface distance, fixation mechanism, screw pattern, working length and manufacturing techniques.Although variations within studies challenge direct translation of experimental results into clinical practice, this review serves as a useful reference guide to determine which parameters must be carefully considered during the design and manufacturing process to achieve the desired biomechanical properties of a plate for fixation of a specific type of fracture.

Accuracy of osseointegrated screw-bone construct stiffness and peri-implant loading predicted by homogenized FE models relative to micro-FE models

Computational predictions of stiffness and peri-implant loading of screw-bone constructs are highly relevant to investigate and improve bone fracture fixations. Homogenized finite element (hFE) models have been used for this purpose in the past, but their accuracy has been questioned given the numerous simplifications, such as neglecting screw threads and modelling the trabecular bone structure as a continuum. This study aimed to investigate the accuracy of hFE models of an osseointegrated screw-bone construct when compared to micro-FE models considering the simplified screw geometry and different trabecular bone material models. Micro-FE and hFE models were created from 15 cylindrical bone samples with a virtually inserted, osseointegrated screw (fully bonded interface). Micro-FE models were created including the screw with threads (=reference models) and without threads to quantify the error due to screw geometry simplification. In the hFE models, the screws were modelled without threads and four different trabecular bone material models were used, including orthotropic and isotropic material derived from homogenization with kinematic uniform boundary conditions (KUBC), as well as from periodicity-compatible mixed uniform boundary conditions (PMUBC). Three load cases were simulated (pullout, shear in two directions) and errors in the construct stiffness and the volume average strain energy density (SED) in the peri-implant region were evaluated relative to the micro-FE model with a threaded screw. The pooled error caused by only omitting screw threads was low (max: 8.0%) compared to the pooled error additionally including homogenized trabecular bone material (max: 92.2%). Stiffness was predicted most accurately using PMUBC-derived orthotropic material (error: -0.7 ± 8.0%) and least accurately using KUBC-derived isotropic material (error: +23.1 ± 24.4%). Peri-implant SED averages were generally well correlated (R² ≥ 0.76), but slightly over- or underestimated by the hFE models and SED distributions were qualitatively different between hFE and micro-FE models. This study suggests that osseointegrated screw-bone construct stiffness can be predicted accurately using hFE models when compared to micro-FE models and that volume average peri-implant SEDs are well correlated. However, the hFE models are highly sensitive to the choice of trabecular bone material properties. PMUBC-derived isotropic material properties represented the best trade-off between model accuracy and complexity in this study.

The optimal design of 3D-printed lattice bone plate by considering fracture healing mechanism

The biomechanical stimulus is the most important factor for fracture healing and mainly determined by the structural stiffness of bone plate. Currently, the materials commonly used in bone plates are stainless steel and titanium, which often lead to stress shielding effects because of their higher elastic modulus compared with the bone. This article suggests an optimal design method of lattice bone plate based on fracture healing theory. First, the mechanical regulation model with deviatoric strain is established to simulate the tissue differentiation process during fracture healing process. The ratio of the average elastic modulus of callus at the 120th day to the elastic modulus of mature bone is used to characterize the fracture healing rate. Second, the optimal elastic modulus of the design domain is obtained by the optimization mathematical model with the maximum fracture healing rate. Then, the design domain is filled with microstructures, the porosity of which is adjusted to make it possible that the equivalent elastic modulus is equal to the optimized value. And the finite element analysis of the bone plate with microstructure is executed. Finally, the designed lattice bone plates are manufactured through 3D printing, and the mechanical test is carried out. The simulation results indicate that the fracture healing rate is maximum when the elastic modulus of material in design domain is 38 GPa under the constraints of fixation stability. And both the finite element analysis and experiment results show that the designed lattice bone plate meet the strength requirements of fracture internal fixation implants.

Evaluating the biomechanical performance of Ti6Al4V volar plates in patients with distal radius fractures

Purpose: This study aimed to investigate the biomechanical performance of three Ti6Al4V volar plates with the latest designs using a finite element model. Methods: An AO type 23-A3 distal radius fracture and the models of T plate (2.4 mm LCP Volar Distal Radius Plate), V plate (2.4 mm LCP Two-Column Volar Distal Radius Plate) and π Plate (2.4 mm Volar Rim Distal Radius Plate) (all from Depuy Synthes, West Chester, PA, USA, Ti6Al4V) were built in 3D-matic software. After assembling the internal fixation and fractures, we imported these models into the finite element analysis software (ABAQUS). An axial loading of 100 N was added to the distal end of each model. The displacements of total models and implants, the principal strains and the von Mises stresses in the plates were calculated and compared to capture the biomechanical features of the three plates. Results: The T plate, V plate and π plate represented a model displacement of 0.8414 mm, 1.134 mm and 1.936 mm, respectively. The T plate was with the implant displacement of 0.7576 mm, followed by the V plate (0.8802 mm) and the π plate (1.545 mm). The T plate had the smallest principal strain of 0.23%, the V plate showed an intermediate level of 0.28%, and the π plate had a value of 0.72%. The least peak von Mises stress was observed in the V plate with 263.6MPa, and this value was 435.6 MPa and 1050 MPa in the T plate and π plate, respectively. Conclusion: The biomechanical features of three Ti6Al4V volar locking plates in an AO type 23-A3 fracture were described in our analysis. The T plate and the V plate showed similar biomechanical performance while the π plate represented worse performance than the other two plates.