Effect of carbon-fiber-reinforced polyetheretherketone on stress distribution in a redesigned tumor-type knee prosthesis: a finite element analysis

Background: Surgery for bone tumors around the knee often involves extensive resection, making the subsequent prosthetic reconstruction challenging. While carbon fiber-reinforced polyetheretherketone (CF-PEEK) has been widely used in orthopedic implants, its application in tumor-type prosthesis is limited. This study aims to evaluate the feasibility of using 30wt% and 60wt% carbon fiber-reinforced polyetheretherketone (CF30-PEEK and CF60-PEEK) as materials for a redesigned tumor-type knee prosthesis through numerical analysis. Methods: A knee joint model based on CT data was created, and the resection and prosthetic reconstruction were simulated. Three finite element models of the prostheses, representing the initial and updated designs with CoCrMo and CFR-PEEK components, were constructed. Loading conditions during standing and squatting were simulated with forces of 700 N and 2800 N, respectively. Finite element analysis was used to analyze the von Mises stress and stability of all components for each prosthesis type. Results: After improvements in both material and design, the new Type 3 prosthesis showed significantly lower overall stress with stress being evenly distributed. Compared with the initial design, the maximum von Mises stress in Type 3 was reduced by 53.9% during standing and 74.2% during squatting. In the standing position, the maximum stress in the CF30-PEEK femoral component decreased by 57.3% compared with the initial design which was composed of CoCrMo, while the stress in the CF60-PEEK cardan shaft remained consistent. In the squatting position, the maximum stress in the femoral component decreased by 81.9%, and the stress in the cardan shaft decreased by 46.5%. Conclusion: The incorporation of CF30-PEEK effectively transmits forces and reduces stress concentration on the femoral component, while CF60-PEEK in the redesigned cardan shaft significantly reduces stress while maintaining stiffness. The redesigned prosthesis effectively conducts loading force and demonstrates favorable biomechanical characteristics, indicating the promising potential of utilizing CF30-PEEK and CF60-PEEK materials for tumor-type knee prostheses. The findings of this study could provide novel insights for the design and development of tumor-type knee prostheses.

Biomechanical Analysis of Non-Metallic Biomaterial in the Manufacture of a New Knee Prosthesis

The increase in the number of revision surgeries after a total knee replacement surgery reaches 19%. One of the reasons for the majority of revisions relates to the debris of the ultra-high molecular weight polyethylene that serves to facilitate the sliding between the femoral and tibial components. This paper addresses the biomechanical properties of ULTEM^TM 1010 in a totally new knee replacement design, based on one of the commercial models of the Stryker manufacturer. It is designed and produced through additive manufacturing that replaces the tibial component and the polyethylene in such a way as to reduce the pieces that are part of the prosthetic assembly to only two: the femoral and the tibial (the so-called “two-component knee prosthesis”). The cytotoxicity as well as the live/dead tests carried out on a series of biomaterials guarantee the best osteointegration of the studied material. The finite element simulation method guarantees the stability of the material before a load of 2000 N is applied in the bending angles 0°, 30°, 60°, 90°, and 120°. Thus, the non-metallic prosthetic material and approach represent a promising alternative for metal-allergic patients.

Spherical center axial hinge knee prosthesis causes lower contact stress on tibial insert and bushing compared with biaxial hinge knee prosthesis

BACKGROUND

Motion axial system may affect contact stress of hinge knee prosthesis. However, it is unclear which axial system provides the better biomechanical effect. Therefore, the aim of this study was to compare the contact stress and stress distribution on the tibial insert and the bushing of hinge knee prostheses with a biaxial (BA) system and a spherical center axial (SA) system during a gait cycle.

METHODS

Three-dimensional finite-element (FE) models of the prostheses with different motion systems were included. The comparisons between experimental tests and FE analyses were performed to verify the models. Dynamic implicit FE analyses were performed to investigate the peak contact stresses and stress distributions on the tibial insert and the bushing.

RESULTS

The peak contact stresses on the tibial insert and the bushing of the BA prosthesis were higher than those of the SA prosthesis during most gait cycles. The contact time on the bushing is short in the SA prosthesis. The stress distributions on the superior surface of the tibial insert in the BA prosthesis were at the posterior side, but of the SA prosthesis were not fixed.

CONCLUSION

The SA prosthesis has a lower peak contact stress on tibial insert and bushing than the BA prosthesis; in addition, the SA prosthesis has a 'self-adjustment' mechanism which could disperse high stress on the tibial insert to decrease the risk of wear and damage. The comparison could help designers and surgeons to better understand the future design of rotating hinge knee prostheses which should be able to achieve multiaxial motion and complete weight bearing by the tibial condylar to transmit the axial force better.

Spherical center and rotating platform hinged knee prosthesis: Finite-element model establishment, verification and contact analysis

BACKGROUND

Biomechanical study is fundamental for the preclinical evaluation of knee prostheses. However, there are few reports on the contact characteristic investigation in the hinged knee prosthesis. The purpose of this study was to investigate the contact characteristics of a novel hinged knee prosthesis.

METHODS

All of the component models were designed and assembled using Solidworks. A comparison of the contact area and ultra-high-molecular-weight polyethylene (UHMWPE) deformation using the experimental method (EM) and finite-element analysis (FEA) under 3000 N with the prosthesis at different flexions was performed. The peak contact pressure and von Mises stress on tibial insert and bushing were investigated under nine specific samples that were extracted from a gait cycle using FEA (according to ISO 14243-1: 2009).

RESULTS

The largest contact area and UHMWPE deformation were 100.78 ± 8.71 mm² and 0.085 ± 0.015 mm in the EM, and 96.68 mm² and 0.096 mm in FEA. The peak contact pressure and von Mises stress on the tibial insert were 26.3071 MPa and 10.5115 MPa at 13% of the gait cycle and on bushing were consistently 0 MPa. The contact pressures were distributed at the posterior of the insert.

CONCLUSION

The finite-element model was validated to be applicable for predicting the real prosthesis behavior based on the good correlation of the results using the EM and FEA. The model can help to identify contact characteristics and be can used in optimization studies of this novel prosthesis during the design phase.