Heterogeneous material mapping methods for patient-specific finite element models of pelvic trabecular bone: A convergence study

Effect of pedicle screw misplacement on the pull-out strength using personalized finite element modeling

Intraoperative misplacement of vertebral pedicle screws is prevalent. While a pedicle screw misplacement of up to 4 mm is often considered safe by clinical standards, this may reduce the pull-out strength thereby increasing the risk of postoperative screw loosening. This study aimed to compare the pull-out strength of ideally-placed and misplaced pedicle screws via personalized finite element (FE) modeling simulations. Three-dimensional FE models to simulate pull-out tests of pedicle screws were constructed. Vertebral geometries and material properties were both determined based on computed tomography images from lumbar spine (L1-L5) of a 29-year-old healthy male individual. Pedicle screws were bilaterally placed under four conditions: ideal placement (no cortex perforation) as well as minor medial, minor lateral, and severe lateral misplacements causing cortex perforations. Minor and severe misplacements corresponded to, respectively, grades C and D of the Gertzbein classification. After meshing and voxel-based vertebral material assignments based on two distinct mappings from literature, pull-out strengths were estimated by considering a strain-based damage model to accurately simulate bone fractures. Results indicated that the mean of FE-predicted pull-out forces for ideally-placed screws (1583 and 2412 N for material mappings 1 and 2, respectively) was within the range of previous experimental data (ranging from 1016 to 2443 N) thus confirming the model validation. The mean of all pull-out forces for each misplaced screw group was significantly smaller (p < 0.05) than that of the ideally-placed screws, e.g., 20 % for minor medial, 22 % for minor lateral, and 37 % for severe lateral misplacements. These findings indicated that even clinically-acceptable screw misplacements (up to 4 mm) could significantly reduce the pull-out strengths of pedicle screws thus imposing higher risk of postoperative screw loosening. To avoid these common screw misplacements, the use of advanced approaches for pedicle screw placements appears to be imperative.

Reduction of material groups for vertebral bone finite element simulation: cross comparison of grouping methods

In patient-specific biomechanical modeling, the process of image-to-mesh-material mapping is important, and various strategies have been explored for assigning the number of groups of unique material properties to the mesh. This study aims to cross-compare different grouping strategies to identify the minimum number of unique groups necessary for accurately calculating the fracture load of vertebral bones. We analyzed 12 vertebral specimens by experimentally determining the biomechanical fracture load and acquiring corresponding CT scans. After geometry extraction and meshing, we applied commonly used fixed-value strategies for reducing the number of unique groups, such as Modulus Gaping and Percentual Thresholding. Additionally, we introduced a patient-specific adaptive grouping method based on K-means clustering, which allowed us to maintain a consistent number of groups of unique material properties across the study. A total of 204 simulations were performed, achieving a potential 98% reduction in the number of individual material parameters while maintaining a strong correlation with experimental results when utilizing Percentual Thresholding or Adaptive Clustering, compared to Modulus Gaping. The findings demonstrate the feasibility of significantly reducing simulation complexity while maintaining the accuracy of patient-specific models that strongly correlate with experimental results. This reduction enables efficient processing of patient-specific biomechanical models derived from image data, offering potential benefits for clinicians, particularly in resource-constrained settings.

A novel personalized homogenous finite element model to predict the pull-out strength of cancellous bone screws

BACKGROUND

Orthopedic surgeries often involve the insertion of bone screws for various fixation systems. The risk of postoperative screw loosening is usually assessed through experimental or finite element (FE) evaluations of the screw pull-out strength. FE simulations are based on either personalized complex but accurate heterogeneous modeling or non-personalized simple but relatively less accurate homogeneous modeling. This study aimed to develop and validate a novel personalized computed tomography (CT)-based homogeneous FE simulation approach to predict the pull-out force of cancellous bone screws.

METHODS

Twenty FE simulations of L1-L5 vertebral screw pull-out tests were conducted, i.e., 10 heterogeneous and 10 homogenous models. Screws were inserted into the lower-middle region of vertebrae. In our novel homogeneous model, the region around approximately twice the diameter of the screw was used as a bone material reference volume. Subsequently, the overall material property of this region was homogeneously attributed to the entire vertebra, and pull-out simulations were conducted.

RESULTS

The mean error of the predicted pull-out forces by our novel homogenous simulations was ~ 7.9% with respect to our heterogeneous model. When solely the cancellous bone was involved during the pull-out process (i.e., for L1, L2, and L3 vertebral bodies whose cortical bone in the inferior region is thin), the novel homogenous model yielded small mean error of < 6.0%. This error, however, increased to ~ 11% when the screw got involved to the cortical bone (for L4 and L5 vertebrae whose cortical bone in the inferior region is thick).

CONCLUSION

The proposed personalized CT-based homogenous model was highly accurate in estimating the pull-out force especially when only the cancellous bone was involved with the screw.

Evaluation of finite element modeling methods for predicting compression screw failure in a custom pelvic implant

Introduction: Three-dimensional (3D)-printed custom pelvic implants have become a clinically viable option for patients undergoing pelvic cancer surgery with resection of the hip joint. However, increased clinical utilization has also necessitated improved implant durability, especially with regard to the compression screws used to secure the implant to remaining pelvic bone. This study evaluated six different finite element (FE) screw modeling methods for predicting compression screw pullout and fatigue failure in a custom pelvic implant secured to bone using nine compression screws. Methods: Three modeling methods (tied constraints (TIE), bolt load with constant force (BL-CF), and bolt load with constant length (BL-CL)) generated screw axial forces using functionality built into Abaqus FE software; while the remaining three modeling methods (isotropic pseudo-thermal field (ISO), orthotropic pseudo-thermal field (ORT), and equal-and-opposite force field (FOR)) generated screw axial forces using iterative physics-based relationships that can be implemented in any FE software. The ability of all six modeling methods to match specified screw pretension forces and predict screw pullout and fatigue failure was evaluated using an FE model of a custom pelvic implant with total hip replacement. The applied hip contact forces in the FE model were estimated at two locations in a gait cycle. For each of the nine screws in the custom implant FE model, likelihood of screw pullout failure was predicted using maximum screw axial force, while likelihood of screw fatigue failure was predicted using maximum von Mises stress. Results: The three iterative physics-based modeling methods and the non-iterative Abaqus BL-CL method produced nearly identical predictions for likelihood of screw pullout and fatigue failure, while the other two built-in Abaqus modeling methods yielded vastly different predictions. However, the Abaqus BL-CL method required the least computation time, largely because an iterative process was not needed to induce specified screw pretension forces. Of the three iterative methods, FOR required the fewest iterations and thus the least computation time. Discussion: These findings suggest that the BL-CL screw modeling method is the best option when Abaqus is used for predicting screw pullout and fatigue failure in custom pelvis prostheses, while the iterative physics-based FOR method is the best option if FE software other than Abaqus is used.

A statistical analysis of human talar shape and bone density distribution

The shape of the talus, its internal structure, and its mechanical properties are important in determining talar behavior during loading, which may be significant for the design of surgical tools and implants. Although recent studies using statistical shape modeling have described quantitative talar external shape variation, no similar quantitative study exists to describe the density distribution of internal talar structure. The goal of this study is to quantify statistical variation in talar shape and density to benefit the design of talar implants. To this end, weight-bearing computed tomography (CT) scans of the ankle were collected in neutral, bilateral standing posture, and three-dimensional models were generated for each talus. Local density derived from the Hounsfield unit of each CT voxel was extracted. A weighted spherical harmonic analysis was performed to quantify the talar external shape. One hundred and seventy-nine volumes of interest were placed in the same relative position within each talus to quantify the talar density. Additionally, a finite element analysis (FEA) was conducted on a talus with both heterogeneous and homogeneous material properties to observe the effect of these properties on the stress and strain response. Significant differences were found in the talar density in sex and age, as well as in the stress and strain response between homogeneous and heterogeneous FEA. These differences show the importance of considering heterogeneity when examining the load response of tarsal bones.

Finite element analysis of screw fixation durability under multiple boundary and loading conditions for a custom pelvic implant

Despite showing promising functional outcomes for pelvic reconstruction after sarcoma resection, custom-made pelvic implants continue to exhibit high complication rates due to fixation failures. Patient-specific finite element models have been utilized by researchers to evaluate implant durability. However, the effect of assumed boundary and loading conditions on failure analysis results of fixation screws remains unknown. In this study, the postoperative stress distributions in the fixation screws of a state-of-the-art custom-made pelvic implant were simulated, and the risk of failure was estimated under various combinations of two bone-implant interaction models (tied vs. frictional contact) and four load cases from level-ground walking and stair activities. The study found that the average weighted peak von Mises stress could increase by 22-fold when the bone-implant interactions were modeled with a frictional contact model instead of a tied model, and the likelihood of fatigue and pullout failure for each screw could change dramatically when different combinations of boundary and loading conditions were used. The inclusion of additional boundary and loading conditions led to a more reliable analysis of fixation durability. These findings demonstrated the importance of simulating multiple boundary conditions and load cases for comprehensive implant design evaluation using finite element analysis.

Computational evaluation of psoas muscle influence on walking function following internal hemipelvectomy with reconstruction

An emerging option for internal hemipelvectomy surgery is custom prosthesis reconstruction. This option typically recapitulates the resected pelvic bony anatomy with the goal of maximizing post-surgery walking function while minimizing recovery time. However, the current custom prosthesis design process does not account for the patient's post-surgery prosthesis and bone loading patterns, nor can it predict how different surgical or rehabilitation decisions (e.g., retention or removal of the psoas muscle, strengthening the psoas) will affect prosthesis durability and post-surgery walking function. These factors may contribute to the high observed failure rate for custom pelvic prostheses, discouraging orthopedic oncologists from pursuing this valuable treatment option. One possibility for addressing this problem is to simulate the complex interaction between surgical and rehabilitation decisions, post-surgery walking function, and custom pelvic prosthesis design using patient-specific neuromusculoskeletal models. As a first step toward developing this capability, this study used a personalized neuromusculoskeletal model and direct collocation optimal control to predict the impact of ipsilateral psoas muscle strength on walking function following internal hemipelvectomy with custom prosthesis reconstruction. The influence of the psoas muscle was targeted since retention of this important muscle can be surgically demanding for certain tumors, requiring additional time in the operating room. The post-surgery walking predictions emulated the most common surgical scenario encountered at MD Anderson Cancer Center in Houston. Simulated post-surgery psoas strengths included 0% (removed), 50% (weakened), 100% (maintained), and 150% (strengthened) of the pre-surgery value. However, only the 100% and 150% cases successfully converged to a complete gait cycle. When post-surgery psoas strength was maintained, clinical gait features were predicted, including increased stance width, decreased stride length, and increased lumbar bending towards the operated side. Furthermore, when post-surgery psoas strength was increased, stance width and stride length returned to pre-surgery values. These results suggest that retention and strengthening of the psoas muscle on the operated side may be important for maximizing post-surgery walking function. If future studies can validate this computational approach using post-surgery experimental walking data, the approach may eventually influence surgical, rehabilitation, and custom prosthesis design decisions to meet the unique clinical needs of pelvic sarcoma patients.

From computed tomography to finite element space: A unified bone material mapping strategy

BACKGROUND

The spatially varying mechanical properties in finite element models of bone are most often derived from bone density data obtained via quantitative computed tomography. The key step is to accurately and efficiently map the density given in voxels to the finite element mesh.

METHODS

The density projection is first formulated in least-squares terms and then discretized using a continuous and discontinuous variant of the finite element method. Both discretization variants are compared with the nodal and element approaches known from the literature.

FINDINGS

In terms of accuracy in the L2 norm, energy distance and efficiency, the discontinuous zero-order variant appears to be the most advantageous. The proposed variant sufficiently preserves the spectrum of density at the edges, while keeping computational cost low.

INTERPRETATION

The continuous finite element method is analogous to the nodal formulation in the literature, while the discontinuous finite element method is analogous to the element formulation. The two variants differ in terms of implementation, computational cost and ability to preserve the density spectrum. These differences cannot be described and measured by known indirect methods from the literature.