A Muscle-Driven Spine Model for Predictive Simulations in the Design of Spinal Implants and Lumbar Orthoses

Knowledge of realistic loads is crucial in the engineering design process of medical devices and for assessing their interaction with the spinal system. Depending on the type of modeling, current numerical spine models generally either neglect the active musculature or oversimplify the passive structural function of the spine. However, the internal loading conditions of the spine are complex and greatly influenced by muscle forces. It is often unclear whether the assumptions made provide realistic results. To improve the prediction of realistic loading conditions in both conservative and surgical treatments, we modified a previously validated forward dynamic musculoskeletal model of the intact lumbosacral spine with a muscle-driven approach in three scenarios. These exploratory treatment scenarios included an extensible lumbar orthosis and spinal instrumentations. The latter comprised bisegmental internal spinal fixation, as well as monosegmental lumbar fusion using an expandable interbody cage with supplementary posterior fixation. The biomechanical model responses, including internal loads on spinal instrumentation, influences on adjacent segments, and effects on abdominal soft tissue, correlated closely with available in vivo data. The muscle forces contributing to spinal movement and stabilization were also reliably predicted. This new type of modeling enables the biomechanical study of the interactions between active and passive spinal structures and technical systems. It is, therefore, preferable in the design of medical devices and for more realistically assessing treatment outcomes.

Global stiffness and residual stresses in spinal fixator systems: A validated finite element study on the interconnection mechanism

Posterior spinal fixation systems are the gold standard to treat different column disorders using rods and screws. The proper connection between them is guaranteed by the Interconnection Mechanism (IM), consisting of different metallic subcomponents held together through the application of tightening torque. The response of the fixation system is defined by its overall stiffness, which in turn is governed by the local residual stress field arising during tightening. Although literature computational models for studying spinal fixation are becoming increasingly anatomically complex, most studies disregard completely the realistic modeling of the IM, namely choosing elastic-plastic material models and proper contact interactions. In this frame, the present study aims at increasing awareness in the field of spinal fixation modeling by investigating the mechanical response of the IM in terms of overall stiffness and local residual stresses. Once validated through dedicated experiments, the results of the proposed model have been compared with the current literature, highlighting the key role of the IM in the reliable modeling of spinal fixation.

A Biomechanical Model for Testing Cage Subsidence in Spine Specimens with Osteopenia or Osteoporosis Under Permanent Maximum Load

BACKGROUND

Intervertebral fusions in cases of reduced bone density are a tough challenge. From a biomechanical point of view, most current studies have focused on the range of motion or have shown test setups for single-component tests. Definitive setups for biomechanical testing of the primary stability of a 360° fusion using a screw-rod system and cage on osteoporotic spine are missing. The aim of this study was to develop a test stand to provide information about the bone-implant interface under reproducible conditions.

METHODS

After pretesting with artificial bone, functional spine units were tested with 360° fusion in the transforaminal lumbar interbody fusion technique. The movement sequences were conducted in flexion/extension, right and left lateral bending, and right and left axial rotation on a human model with osteopenia or osteoporosis under permanent maximum load with 7.5 N-m.

RESULTS

During the testing of human cadavers, 4 vertebrae were fully tested and were inconspicuous even after radiological and macroscopic examination. One vertebra showed a subsidence of 2 mm, and 1 vertebra had a cage collapsed into the vertebra.

CONCLUSIONS

This setup is suitable for biomechanical testing of cyclical continuous loads on the spine with reduced bone quality or osteoporosis. The embedding method is stable and ensures a purely single-level setup with different trajectories, especially when using the cortical bone trajectory. Optical monitoring provides a very accurate indication of cage movement, which correlates with the macroscopic and radiological results.

Partial Threading of Pedicle Screws in a Standard Construct Increases Fatigue Life: A Biomechanical Analysis

This study proposed a pedicle screw design where the proximal 1/3 of the screw is unthreaded to improve fixation in posterior spinal surgery. This design was also expected to reduce the incidence of mechanical failure often observed when an unsupported screw length is exposed outside the vertebra in deformed or degenerated segments. The aim of this study was to evaluate the fatigue life of the novel pedicle screw design using finite element analysis and mechanical testing in a synthetic spinal construct in accordance with American Society for Testing and Materials (ASTM) F1717. The following setups were evaluated: (i) pedicle screw fully inserted into the test block (EXP-FT-01 and EXP-PU-01; full thread (FT), proximal unthread (PU)) and (ii) pedicle screw inserted but leaving an exposed shaft length of 7.6 mm (EXP-FT-02 and EXP-PU-02). Corresponding finite element models FEM-FT-01, FEM-FT-02, FEM-PU-01, and FEM-PU-02 were also constructed and subjected to the same loading conditions as the experimental groups. The results showed that under a 220 N axial load, the EXP-PU-01 group survived the full 5 million cycles, the EXP-PU-02 group failed at 4.4 million cycles on average, and both EXP-FT-01 and EXP-FT-02 groups failed after less than 1.0 million cycles on average, while the fatigue strength of the EXP-FT-02 group was the lowest at 170 N. The EXP-FT-01 and EXP-FT-02 constructs failed through fracture of the pedicle screw, but a rod fractured in the EXP-PU-02 group. In comparison to the FEM-FT-01 model, the maximum von Mises stress on the pedicle screw in the FEM-PU-01 and FEM-PU-02 models decreased by −43% and −27%, respectively. In conclusion, this study showed that having the proximal 1/3 of the pedicle screw unthreaded can reduce the risk of screw fatigue failure when used in deformed or degenerated segments.

Clinically relevant finite element technique based protocol to evaluate growing rods for early onset scoliosis correction

OBJECTIVE

The emergence of distraction-based growing rods has provided the means to reduce the progression of spinal deformity in early onset scoliosis (EOS). The current protocols for evaluating spinal implants (ie, ASTM-F1717 and ISO-12189) were developed for fusion/dynamic devices. These protocols do not feature long unsupported rod lengths subjected to distraction. Due to the unsuitability of the existing guidelines for the evaluation of growing rods, a new distraction-based finite element protocol is presented herein for the first time.

METHOD

A vertebrectomy (VO) model from current protocols was modified to accommodate multi-spinal segments (ie, MS model) in which springs with appropriate stiffness were simulated in between the plastic blocks. To assess the efficacy of the protocol, two different computational studies were conducted: (a) compression-bending (MS-CB) with no distraction, and (b) distraction followed by compression-bending (MS-D + CB). In each study, the model with no axial connector (rods-only) was modified to include a) 80-mm long tandem (LT) connectors, and b) side-by-side (SBS) connectors. Stiffness and yield loads were calculated as per ASTM-F1717 guidelines and compared with the corresponding VO models with no distraction. In the MS-D + CB models, distraction was applied at the top block, stretching the spring-block construct in a simulation of scoliosis surgery prior to locking the construct at the connector-rods' interface.

RESULTS

MS-CB models predicted higher stiffness and yield loads, compared to the VO models. The locking mechanism produced pre-existing stresses on the rod-connector interface, which caused a shift in the location of high-stress regions to the distraction site. Distraction led to a decrease in the construct's stiffness and yield load.

DISCUSSION

The proposed protocol enables the simulation of clinical parameters that are not feasible in the F1717 models and predicted stress patterns in the hardware consistent with observed clinical failures.

Effects of pre-contoured and in situ contoured rods on the mechanical strength and durability of posterior cervical instrumentation: a finite-element analysis and scanning electron microscopy investigation

STUDY DESIGN

Finite-element analysis.

OBJECTIVES

Intraoperative contouring of rods is a common procedure for spine surgeons to match the native curvature of the spine, but it may lead to premature weakening of the rod. This study investigated the effect of different bending methods on rod fatigue performance. Rod failure in the cervical spine is of clinical concern, particularly when spanning the cervicothoracic region and when considering corrective osteotomies for deformity correction and global spinal alignment.

METHODS

Finite-element models were developed to simulate rod bending (3.5 mm D, 40 mm L) to achieve a 23° angle with 3 different bending methods: French single, multiple bending, and in situ bending. Simulations were conducted in 4 steps: rod bending, rod spring back, residual stress relaxation, and F1717 mechanical test simulation.

RESULTS

French single bending resulted in the highest residual stress concentrations for both titanium (TiAlV) and cobalt chrome (CoCr) at 783 MPa and 507 MPa, respectively. During F1717 test simulation, the French single bent rod had its highest tensile stress in the middle, with 917 MPa and 623 MPa, respectively, for TiAlV and CoCr, compared to in situ (580 MPa and 586 MPa for TiAlV and CoCr) and the French multiple bent rod (765 MPa and 619 MPa for TiAlV and CoCr). The computational model found that CoCr rods made the construct least prone to deformation.

CONCLUSIONS

French single bend with TiAlV rods put the construct at highest risk of failure. CoCr rods led to minimal physical changes in microstructure while showing evidence of flattening.

Incomplete insertion of pedicle screws in a standard construct reduces the fatigue life: A biomechanical analysis

Pedicle screws are commonly used for posterior stabilization of the spine. When used in deformed or degenerated segments, the pedicle screws are often not fully inserted into the bone, but instead the threaded portion is exposed by 1 or 2 threads to accommodate rod placement and ensure alignment between the tulip of the screw and the rod. However, broken pedicle screws have been reported with the use of this method. The aim of this study was to determine how the fatigue life of the screw is affected by not fully inserting the screw into the bone. Spinal constructs were evaluated in accordance with ASTM F1717. The following three screw positions were subjected to compression bending fatigue loading; (i) pedicle screw fully inserted in the test block with no threads exposed (EXP-T0), (ii) pedicle screw inserted with one thread exposed outside the test block (EXP-T1), (iii) pedicle screw inserted with two threads exposed outside the test block (EXP-T2). Corresponding finite element models FEM-T0, FEM-T1 and FEM-T2 were also constructed and subjected to the same axial loading as the experimental groups to analyze the stress distribution in the pedicle screws and rods. The results showed that under a 190 N axial load, the EXP-T0 group survived the full 5 million cycles, the EXP-T1 group failed at 3.7 million cycles on average and the EXP-T2 groups failed at 1.0 million cycles on average, while the fatigue strength of both the EXP-T1 and EXP-T2 groups was 170 N. The constructs failed through fracture of the pedicle screw. In comparison to the FEM-T0 model, the maximum von Mises stress on the pedicle screw in the FEM-T1 and FEM-T2 models increased by 39% and 58%, respectively. In conclusion, this study demonstrated a drastic decrease in the fatigue life of pedicle screws when they are not full inserted into the plastic block.

Bicortical Screw Purchase at Upper Instrumented Vertebra (UIV) Can Cause UIV Fracture After Adult Spinal Deformity Surgery: A Finite Element Analysis Study

OBJECTIVE

To examine the biomechanical stress distribution at the upper instrumented vertebra (UIV) according to unicortical- and bicortical purchase model by finite element analysis (FEA).

METHODS

A T8 to Sacrum with implant finite element model was developed and validated. The pedicle screws were unicortically or bicortically inserted from T10 to L5, and each model was compared and the von Mises (VM) yield stress of T10 was calculated. According to the motion (flexion, extension, lateral bending, and axial rotation) of spine, boundary condition values were set as 15°, 15°, 10°, 4°.

RESULTS

Although the 2 stress values did not show a significant difference between the unicortical- and bicortical purchase models in the flexion and extension, bicortical purchase model showed a larger stress distribution. However, the asymmetric behavior was significantly greater in the case of lateral bending (0.802 MPa vs. 0.489 MPa) and the rotation (5.545 MPa vs. 4.905 MPa). The greater stress was observed on the spinal body surface abutting the implanted screw. Although the maximum stress was observed around the implanted screw in the bicortical purchase model under axial loading, the VM stress of both models was not significantly different.

CONCLUSION

Bicortical purchase model showed a larger stress distribution than the unicortical model, especially in the case of lateral bending and the rotation behavior. Our biomechanical simulation by FEA indicates that bicortical fixation at UIV can be a risk factor for early UIV compression fracture after adult spinal deformity surgery.

Biomechanical analysis of spinal implants with different rod diameters under static and fatigue loads: an experimental study

Spinal implants are commonly used in the treatment of spinal disorders or injuries. However, the biomechanical analyses of them are rarely investigated in terms of both biomechanical and clinical perspectives. Therefore, the main purpose of this study is to investigate the effects of rod diameter on the biomechanical behavior of spinal implants and to make a comparison among them. For this purpose, three spinal implants composed of pedicle screws, setscrews and rods, which were manufactured from Ti6Al4V, with diameters of 5.5 mm, 6 mm and 6.35 mm were used and a bilateral vertebrectomy model was applied to spinal systems. Then, the obtained spinal systems were tested under static tension-compression and fatigue (dynamic compression) conditions. Also, failure analyses were performed to investigate the fatigue behavior of spinal implants. After static tension-compression and fatigue tests, it was found that the yield loads, stiffness values, load carrying capacities and fatigue performances of spinal implants enhanced with increasing spinal rod diameter. In comparison to spinal implants with 5.5 mm rods, the fatigue limits of implants showed 13% and 33% improvements in spinal implants having 6 mm and 6.35 mm rods, respectively. The highest static and fatigue test results were obtained from spinal implants having 6.35 mm rods among the tested implants. Also, it was observed that the increasing yield load and stiffness values caused an increase in the fatigue limits of spinal implants.

Material failure in dynamic spine implants: are the standardized implant tests before market launch sufficient?

PURPOSE

International Standards Organization (ISO) 12189 and American Society for Testing and Materials F2624 are two standard material specification and test methods for spinal implant devices. The aim of this study was to assess whether the existing and required tests before market launch are sufficient.

METHODS

In three prospective studies, patients were treated due to degenerative disease of the lumbar spine or spondylolisthesis with lumbar interbody fusion and dynamic stabilization of the cranial adjacent level. The CD HORIZON BalanC rod and S⁴ Dynamic rod were implanted in 45 and 11 patients, respectively.

RESULTS

A fatigue fracture of the material of the topping off system has been found in five cases (11%) for the group fitted with the CD HORIZON BalanC rod. In the group using the S⁴ Dynamic rod group, a material failure of the dynamic part was demonstrated in seven patients (64%). All three studies were interrupted due to these results, and a report to the Federal Institute for Drugs and Medical Devices was generated.

CONCLUSION

Spinal implants have to be checked by a notified body before market launch. The notified body verifies whether the implants fulfil the requirements of the current standards. These declared studies suggest that the current standards for the testing of load bearing capacity and stand ability of dynamic spine implants might be insufficient. Revised standards depicting sufficient deformation and load pattern have to be developed and counted as a requirement for the market launch of an implant. These slides can be retrieved under Electronic Supplementary Material.

Toward the definition of a new worst-case paradigm for the preclinical evaluation of posterior spine stabilization devices

Mechanical reliability tests on posterior spine stabilization devices are based on standard F1717 by the American Society for Testing and Materials, which describes how to assemble the implant with vertebrae-like test blocks in a corpectomy model. A recent study proposed to revise the standard to describe the anatomical worst-case scenario, instead of the average one currently implemented, and introduce the unsupported screw length as a mechanical parameter. This article investigates the implications of such revisions on the endurance properties of an implant already on the market. Experimental fatigue tests demonstrate that the revision of F1717 standard leads to a reduction of 3.2 million cycles in the fatigue strength of the tested implant: this amount is comparable to the run-out number of cycles (5 million cycles) currently recommended. The numerical analysis, validated with static tests and strain gauges, supports the experimental findings and demonstrates that the stress on the implant may increase upon revision up to a 50% on the screw (most recurrent failure mode), with the unsupported screw length contributing alone up to 40%. The revision of ASTM F1717 standard would guarantee higher safety for the implant to test, potentially covering for a wider population of patients.

Preclinical evaluation of posterior spine stabilization devices: can the current standards represent basic everyday life activities?

PURPOSE

To discuss whether the available standard methods for preclinical evaluation of posterior spine stabilization devices can represent basic everyday life activities and how to compare the results obtained with different procedures.

METHODS

A comparative finite element study compared ASTM F1717 and ISO 12189 standards to validated instrumented L2-L4 segments undergoing standing, upper body flexion and extension. The internal loads on the spinal rod and the maximum stress on the implant are analysed.

RESULTS

ISO recommended anterior support stiffness and force allow for reproducing bending moments measured in vivo on an instrumented physiological segment during upper body flexion. Despite the significance of ASTM model from an engineering point of view, the overly conservative vertebrectomy model represents an unrealistic worst case scenario. A method is proposed to determine the load to apply on assemblies with different anterior support stiffnesses to guarantee a comparable bending moment and reproduce specific everyday life activities.

CONCLUSIONS

The study increases our awareness on the use of the current standards to achieve meaningful results easy to compare and interpret.

ISO 12189 standard for the preclinical evaluation of posterior spinal stabilization devices--II: A parametric comparative study

The International Standardization Organization (ISO) 12189 standard was recently introduced to preclinically evaluate and compare the mechanical properties of posterior stabilization devices. This scenario presents some new significant steps ahead over the vertebrectomy model recommended by American Society for Testing and Materials (ASTM) F1717 standard: the modular anterior support allows for describing a closer scenario to the effective clinical use as well as to test very flexible and dynamic posterior stabilization devices. Despite these significant advantages, ISO 12189 received little attention in the literature. Anatomical parameters depending on the spinal level were compared to the published data or original measurements on biplanar stereoradiography on 13 patients. Other mechanical variables, describing the test set-up design, were considered and all parameters were investigated using a numerical parametric finite element model. Stress values were calculated by also considering their worst-case combination. The standard set-up represents quite well the anatomy of an instrumented average thoracolumbar segment. The parametric comparative analysis demonstrates a significant (even beyond +350%) maximum increase in the stress on the device, compared to the standard currently in use. The anterior support stiffness plays the most detrimental effect (maximum stress increases up to 396%). The initial precompression step has an important role in determining the final stress values achieved at peak load (up to +76%). Moreover, when combining these two contributions, an even higher stress increase may be achieved (up to 473%). Despite the other anatomical parameters playing a secondary role, their worst-case combination demonstrates that a device could potentially undergo higher stresses than those reached according to standard suggestions (maximum increase of 22.4% at L1). Any user/designer should be aware of these effects when using ISO 12189 standard for the preclinical evaluation of posterior spinal stabilization devices.

ISO 12189 standard for the preclinical evaluation of posterior spinal stabilization devices--I: Assembly procedure and validation

The International Standardization Organization introduced standard 12189 for the preclinical evaluation of the mechanical reliability of posterior stabilization devices. The well-known vertebrectomy model formalized in standard F1717 by the American Society for Testing and Materials was modified with the introduction of a modular anterior support made up of three calibrated springs, which allows to describe a more realistic scenario, closer to the effective clinical use, as well to test even very flexible and dynamic posterior stabilization implants. Despite these important improvements, ISO 12189 received very little attention in the literature. The aim of the work is to provide a systematic procedure for the assembly and validation of a finite element model capable of describing the experimental test according to ISO 12189. The validated finite element model is able to catch very well the effective stiffness of the unassembled and assembled constructs (percentage differences <2% and <10%, respectively). As concern the assembled construct, the experimentally measured and predicted strains were found in a good agreement (R2 > 0.75, root mean square error < 30%), but the procedure without precompression lead to much better results (R2 > 0.96, root mean square error < 10%). Given the prediction errors of the assembled construct fall within the experimental range of repeatability, the finite element model can be systematically implemented to support the mechanical design of a variety of spinal implants, to quantitatively investigate the load-sharing mechanism, as well as to investigate the loading conditions set by ISO 12189 standard.