Clinical and histologic results related to a low-modulus composite total hip replacement stem

Patient-specific femoral implant design using metamaterials for improving load transfer at proximal-lateral region of the femur

Loading configuration of hip joint creates resultant bending effect on femoral implants. So, the lateral side of femoral implant which is under tension retracts from peri‑implant bone due to positive Poisson's ratio. This retraction of implant leads to load shielding and gap opening in proximal-lateral region, thereby allowing entry of wear particle to implant-bone interface. Retraction of femoral implant can be avoided by introducing auxetic metamaterial to the retracting side. This allows the implant to push peri‑implant bone under tensile condition by virtue of their auxetic (negative Poisson's ratio) nature. To develop such implants, a patient-specific conventional solid implant was first designed based on computed-tomography scan of a patient's femur. Two types of metamaterials (2D: type-1) and (3D: type-2) were employed to design femoral meta-implants. Type-1 and type-2 meta-implants were fabricated using metallic 3D printing method and mechanical compression testing was conducted. Three finite element (FE) models of the femur implanted with solid implant, type-1 meta-implant and type-2 meta-implant were developed and analysed under compression loading. Significant correlation (R² = 0.9821 and R² = 0.9977) was found between the experimental and FE predicted strains of the two meta-implants. In proximal-lateral region of the femur, an increase of 7.1% and 44.1% von-Mises strain was observed when implanted with type-1 and type-2 meta-implant over the solid implant. In this region, bone remodelling analysis revealed 2.5% bone resorption in case of solid implant. While bone apposition of 0.5% and 7.7% was observed in case of type-1 and type-2 meta-implants, respectively. The results of this study indicates that concept of introduction of metamaterial to the lateral side of femoral implant can prove to provide higher osseointegration-friendly environment in the proximal-lateral region of femur.

Dual-Energy X-Ray Absorptiometry (DEXA) Evaluation of the Bone Remodeling Effects of a Low-Modulus Composite Hip Stem After 2 Decades of Follow-Up

Background: The Epoch FullCoat Hip Stem (Zimmer) was an isoelastic composite femoral stem developed to address stem stiffness concerns. Purpose: We sought to evaluate the long-term bone mineral density (BMD) of a cohort of patients who underwent total hip arthroplasty (THA) using the Epoch isoelastic stem and having more than 2-decade follow-up. Methods: We conducted a retrospective chart review of all patients who were study subjects at our institution in a multicenter prospective trial for the Food and Drug Administration of the Epoch implant in the mid-1990s. Through this, we identified 16 patients who had dual-energy X-ray absorptiometry (DEXA) scans, with which we could determine BMD preoperatively and at 3 points postoperatively. Of these, 5 agreed to participate in the study (the others were deceased, unable or declined to participate, or were lost to follow-up) with mean follow-up of 22 years. These participants underwent clinical and radiographic evaluation consisting of a Harris hip score, anteroposterior (AP) pelvis and AP and lateral hip X-rays, and DEXA evaluation of both hips. BMD in the 7 Gruen zones at last follow-up was compared with immediate postoperative and 2-year follow-up. Results: At last follow-up, all stems were well-fixed with signs of extensive osteointegration. In proximal Gruen zones 1 and 7, patients underwent a decrease in BMD with more modest losses in Gruen zone 1. All patients demonstrated an increase in BMD in zones 2 through 6 at latest follow-up, except for 1 patient in Gruen zone 6. BMD changes were not limited to the first 2 years of follow-up. Conclusion: This small follow-up cohort study found excellent long-term clinical results, no plain radiographic signs of notable stress shielding, and general maintenance of BMD at a follow-up of over 20 years for this isoelastic stem. Long-term bone remodeling after implantation of the isoelastic stem resulted in increased BMD in Gruen zones 2 through 6, suggesting that composite implant designs may still have a role in THA.

Effect of carbon fiber type on monotonic and fatigue properties of orthopedic grade PEEK

Carbon-fiber reinforced (CFR) PEEK implants are used in orthopedic applications ranging from fracture fixation plates to spinal fusion cages. Documented implant failures and increasing volume and variety of CFR PEEK implants warrant a clearer understanding of material behavior under monotonic and cyclic loading. To address this issue, we conducted monotonic and fatigue crack propagation (FCP) experiments on orthopedic grade unfilled PEEK and two formulations of CFR PEEK (PAN- and pitch-based carbon fibers). The effect of annealing on FCP behavior was also studied. Under monotonic loading, fiber type had a statistically significant effect on elastic modulus (12.5 ± 1.3 versus 18.5 ± 2.3 GPa, pitch versus PAN CFR PEEK, AVG ± SD) and on ultimate tensile strength (145 ± 9 versus 192 ± 17 MPa, pitch versus PAN CFR PEEK, AVG ± SD). Fiber type did not have a significant effect on failure strain. Under cyclic loading, PAN CFR PEEK demonstrated an increased resistance to FCP compared with unfilled and pitch CFR PEEK, and this improvement was enhanced following annealing. Pitch CFR PEEK exhibited FCP behavior similar to unfilled PEEK, and neither material was appreciably affected by annealing. The improvements in monotonic and FCP behavior of PAN CFR PEEK is attributed to a compound effect of inherent fiber properties, increased fiber number for an equivalent wt% reinforcement, and fiber aspect ratio. FCP was shown to proceed via cyclic modes during stable crack growth, which transitioned to static modes (more akin to monotonic fracture) at longer crack lengths. The mechanisms of fatigue crack propagation appear similar between carbon-fiber types.

Fully porous 3D printed titanium femoral stem to reduce stress-shielding following total hip arthroplasty

Current hip replacement femoral implants are made of fully solid materials which all have stiffness considerably higher than that of bone. This mechanical mismatch can cause significant bone resorption secondary to stress shielding, which can lead to serious complications such as peri-prosthetic fracture during or after revision surgery. In this work, a high strength fully porous material with tunable mechanical properties is introduced for use in hip replacement design. The implant macro geometry is based off of a short stem taper-wedge implant compatible with minimally invasive hip replacement surgery. The implant micro-architecture is fine-tuned to locally mimic bone tissue properties which results in minimum bone resorption secondary to stress shielding. We present a systematic approach for the design of a 3D printed fully porous hip implant that encompasses the whole activity spectrum of implant development, from concept generation, multiscale mechanics of porous materials, material architecture tailoring, to additive manufacturing, and performance assessment via in vitro experiments in composite femurs. We show that the fully porous implant with an optimized material micro-structure can reduce the amount of bone loss secondary to stress shielding by 75% compared to a fully solid implant. This result also agrees with those of the in vitro quasi-physiological experimental model and the corresponding finite element model for both the optimized fully porous and fully solid implant. These studies demonstrate the merit and the potential of tuning material architecture to achieve a substantial reduction of bone resorption secondary to stress shielding. © 2016 Orthopaedic Research Society. Published by Wiley Periodicals, Inc. J Orthop Res 35:1774-1783, 2017.

Improving peri-prosthetic bone adaptation around cementless hip stems: a clinical and finite element study

This study assessed whether the Symax™ implant, a modification of the Omnifit(®) stem (in terms of shape, proximal coating and distal surface treatment), would yield improved bone remodelling in a clinical DEXA study, and if these results could be predicted in a finite element (FE) simulation study. In a randomized clinical trial, 2 year DEXA measurements between the uncemented Symax™ and Omnifit(®) stem (both n=25) showed bone mineral density (BMD) loss in Gruen zone 7 of 14% and 20%, respectively (p<0.05). In contrast, the FE models predicted a 28% (Symax™) and 26% (Omnifit(®)) bone loss. When the distal treatment to the Symax™ was not modelled in the simulation, bone loss of 35% was predicted, suggesting the benefit of this surface treatment for proximal bone maintenance. The theoretical concept for enhanced proximal bone loading by the Symax™, and the predicted remodelling pattern were confirmed by DEXA-results, but there was no quantitative match between clinical and FE findings. This was due to a simulation based on incomplete assumptions concerning the yet unknown biological and mechanical effects of the new coating and surface treatment. Study listed under ClinicalTrials.gov with number NCT01695213.

Maintenance of a bone collagen phenotype by osteoblast-like cells in 3D periodic porous titanium (Ti-6Al-4 V) structures fabricated by selective electron beam melting

Regular 3D periodic porous Ti-6Al-4 V structures were fabricated by the selective electron beam melting method (EBM) over a range of relative densities (0.17-0.40) and pore sizes (500-1500 µm). Structures were seeded with human osteoblast-like cells (SAOS-2) and cultured for four weeks. Cells multiplied within these structures and extracellular matrix collagen content increased. Type I and type V collagens typically synthesized by osteoblasts were deposited in the newly formed matrix with time in culture. High magnification scanning electron microscopy revealed cells attached to surfaces on the interior of the structures with an increasingly fibrous matrix. The in-vitro results demonstrate that the novel EBM-processed porous structures, designed to address the effect of stress-shielding, are conducive to osteoblast attachment, proliferation and deposition of a collagenous matrix characteristic of bone.

Fixation and bone remodeling around a low-modulus stem seven-year follow-up of a randomized study with use of radiostereometry and dual-energy x-ray absorptiometer

Thirty-eight patients (40 hips) randomly received either an uncemented fully porous-coated composite stem (Epoch; Zimmer, Warsaw, Ind) or an uncemented proximally porous-coated solid stem (Anatomic; Zimmer). Patients were followed up for 7 years using radiostereometry, dual-energy x-ray absorptiometry, conventional radiography, the Harris Hip Score, and a pain questionnaire. Both stem designs achieved excellent outcome for fixation (stem subsidence and stem rotations close to zero) and clinical outcome, without any difference between the 2 groups (P > .12). Median wear rates were low despite use of conventionally gamma-sterilized polyethylene. No stem was radiographically loose on the postoperative radiographs. The low-modulus composite stem had positive effects on early proximal bone remodeling in Gruen regions 1, 2, 6, and 7 (P < .04). However, at 7 years, this bone-sparing effect persisted in only the calcar region (Gruen region 7).

The Frank Stinchfield Award: the impact of socioeconomic factors on outcome after THA: a prospective, randomized study

BACKGROUND

Most studies of total hip arthroplasty (THA) focus on the effect of the type of implant on the clinical result. Relatively little data are available on the impact of the patient's preoperative status and socioeconomic factors on the clinical results following THA.

QUESTIONS/PURPOSES

We determined the relative importance of patient preoperative and socioeconomic status compared to implant and technique factors in predicting patient outcome as reflected by scores on commonly utilized rating scales (eg, Harris Hip Score, WOMAC, SF-12, degree of patient satisfaction, or presence or severity of thigh pain) following cementless THA.

METHODS

All patients during the study period were offered enrollment in a prospective, randomized study to receive either a titanium, tapered, proximally coated stem; or a Co-Cr, cylindrical, extensively coated stem; 102 patients were enrolled. We collected detailed patient data preoperatively including diagnosis, age, gender, insurance status, medical comorbidities, tobacco and alcohol use, household income, educational level, and history of treatment for lumbar spine pathology. Clinical evaluation included Harris Hip Score, SF-12, WOMAC, pain drawing, and UCLA activity rating and satisfaction questionnaire. Implant factors included stem type, stem size, fit in the canal, and stem-bone stiffness ratios. Minimum 2 year followup was obtained in 95% of the enrolled patients (102 patients).

RESULTS

Patient demographics and preoperative status were more important than implant factors in predicting the presence of thigh pain, dissatisfaction, and a low hip score. The most predictive factors were ethnicity, educational level, poverty level, income, and a low preoperative WOMAC score or preoperative SF-12 mental component score. No implant parameter correlated with outcome or satisfaction.

CONCLUSION

Socioeconomic factors and preoperative status have more impact on the clinical outcome of cementless THA than implant related factors.

LEVEL OF EVIDENCE

Level I, prospective, randomized clinical trial. See the guidelines online for a complete description of level of evidence.

Tissue response to the components of a hydroxyapatite-coated composite femoral implant

Bone loss around femoral implants used for THA is a persistent clinical concern. It may be caused by stress shielding, generally attributed to a mismatch in stiffness between the implants and host bone. In this regard, a fatigue resistant, carbon fiber (CF) composite femoral implant with bone-matching stiffness has been developed. This study evaluated the tissue response to the three material components of this implant in normal and textured (blasted with 24 grit alumina) surfaces: the hydroxyapatite (HA) coating, the CF composite and the intermediate crystalline HA particulate composite layer to bond to the HA coating (blended). Sprague-Dawley rats underwent bilateral femoral implantation each receiving two rod-like implants. Bone apposition to the HA (37%) and textured Ti (41%) implants was not significantly different. Bone apposition to the untextured CF (14%) and blended (19%) implants and polished Ti (8%) implants was significantly lower. Bone apposition to the textured CF (9%) and blended (11%) implants was lower (but not statistically from the as received or untextured counterparts). Nearly all sections from femurs containing CF implants presented CF debris. There was no evidence of localized bone loss or any strong immune response associated with any of the implant materials. All materials were well tolerated with minimal inflammation despite the presence of particulate debris. The high degree of bone apposition to the HA-coated composite implants and the lack of short-term inflammation and adverse tissue response to the three material implant component support continued evaluation of this composite technology for use in THA.

Mapping the strain distribution on the proximal femur with titanium and flexible-stemmed implants using digital image correlation

We implanted titanium and carbon fibre-reinforced plastic (CFRP) femoral prostheses of the same dimensions into five prosthetic femora. An abductor jig was attached and a 1 kN load applied. This was repeated with five control femora. Digital image correlation was used to give a detailed two-dimensional strain map of the medial cortex of the proximal femur. Both implants caused stress shielding around the calcar. Distally, the titanium implant showed stress shielding, whereas the CFRP prosthesis did not produce a strain pattern which was statistically different from the controls. There was a reduction in strain beyond the tip of both the implants.

This investigation indicates that use of the CFRP stem should avoid stress shielding in total hip replacement.

Evaluation of the stress distribution in CFR-PEEK dental implants by the three-dimensional finite element method

CFR-PEEK (carbon fiber reforced-poly ether ether ketone) has been demonstrated to be excellent substitute titanium in orthopedic applications and can be manufactured with many physical, mechanical, and surface properties, in several shapes. The aim of this study was to compare, using the three-dimensional finite element method, the stress distribution in the peri-implant support bone of distinct models composed of PEEK components and implants reinforced with 30% carbon fiber (30% CFR-PEEK) or titanium. In simulations with a perfect bonding between the bone and the implant, the 30% CFR-PEEK presented higher stress concentration in the implant neck and the adjacent bone, due to the decreased stiffness and higher deformation in relation to the titanium. However, 30% CFR-PEEK implants and components did not exhibit any advantages in relation to the stress distribution compared to the titanium implants and components.

Bone remodeling in a new biomimetic polymer-composite hip stem

Adaptive bone remodeling is an important factor that leads to bone resorption in the surrounding femoral bone and implant loosening. Taking into account this factor in the design of hip implants is of clinical importance, because it allows the prediction of the bone-density redistribution and enables the monitoring of bone adaptation after prosthetic implantation. In this article, adaptive bone remodeling around a new biomimetic polymer-composite-based (CF/PA12) hip prosthesis is investigated to evaluate the amount of stress shielding and bone resorption. The design concept of this new prosthesis is based on a hollow substructure made of hydroxyapatite-coated, continuous carbon fiber (CF)-reinforced polyamide 12 (PA12) composite with an internal soft polymer-based core. Strain energy density theory coupled with 3D Finite Element models is used to predict bone density redistributions in the femoral bone before and after total hip replacement (THR) using both polymer-composite and titanium (Ti) stems. The result of numerical simulations of bone remodeling revealed that the CF/PA12 composite stem generates a better bone density pattern compared with the Ti-based stem, indicating the effectiveness of the composite stem to reduce bone resorption caused by stress-shielding phenomenon. This may result in an extended lifetime of THR.

Survivorship of a low-stiffness extensively porous-coated femoral stem at 10 years

A novel low-stiffness extensively porous-coated total hip femoral component was designed to achieve stable skeletal fixation, structural durability, and reduced periprosthetic femoral stress shielding. In short- to intermediate-term clinical review, this implant achieved secure biologic fixation and preserved periprosthetic bone. We retrospectively reviewed all 102 prospectively followed patients (106 implants) with this implant to document the longer-term implant survivorship, clinical function, fixation quality, and periprosthetic bone preservation. Ninety-seven patients with 101 implants had current followup or were followed to patient death (range, 1-14 years; average, 10 years). Eighty-six living patients were followed for an average implant survivorship of 10 years. There were no known femoral implant removals. The average Harris hip score at 10-year followup was 98. Radiographs demonstrated secure implant fixation and maintenance of periprosthetic bone. These data suggest this implant design provided long-term function characterized by extensive fixation, structural durability, and radiographic appearance of maintained periprosthetic cortical thickness and density.

LEVEL OF EVIDENCE

Level I, therapeutic study. See Guidelines for Authors for a complete description of levels of evidence.

Biomechanical comparison of 2 proximally coated femoral stems: effects of stem length and surface finish

Proximally hydroxyapatite-coated stems have performed well clinically but produced moderate proximal stress shielding and midstem cancellous condensation. Stem modification (stem shortening and distal tip polishing) has resulted in greater incidence of thigh pain. We performed a retrospective finite element analysis of the effects of stem length and surface finish to determine if midstem fixation could be avoided and the results could relate to the clinical outcomes. The modified short stem not only produced moderately less proximal bone resorption but also exhibited greater instability with 40% to 94% greater bone-implant relative motion at the stem tip. Bone formation potential at the transition between the coated and uncoated regions of both stems was observed based on changes in strain energy density. These findings are consistent with previous radiographic and clinical comparisons of short- and long-stem designs. Increased pain incidence for short-stem patients may be related to decreased implant instability and increased interface relative motion.

Ten-year results of a bone-preserving low-modulus composite total hip replacement stem

A cementless composite femoral stem was developed with the aim of reducing bone loss secondary to stress shielding. Thirty-one stems were implanted in 27 patients, combined with a cementless acetabular component with polyethylene bearing surface in 30 cases and a bipolar head in 1 case. Patients were followed-up annually with clinical and radiographic evaluation. Fourteen hips underwent dual X-ray absorptiometry (DEXA) scans to monitor postoperative bone mineral density around the stem. The mean follow-up was 10.1 years. The mean Harris hip score improved from 57 to 92. To date, no stem has required revision. All stems are radiographically stable. Acetabular component revision has been required in 8 cases; 3 for liner dissociation and 5 for polyethylene wear. Radiographs and DEXA scans have shown some improvement in bone mineral density (BMD) between the 2 and 5-year follow-up. A cohort of patients displayed improvement in radiographic appearance and BMD in Gruen zone 7. This stem shows evidence of proximal bone preservation and has excellent results at medium to long-term follow-up. The limiting factor in our cohort of patients has been the polyethylene bearing surface.

Development of a multi-component fiber-reinforced composite implant for load-sharing conditions

Fiber-reinforced composites (FRC) have the potential for use as load-bearing orthopaedic implants if the high strength and elastic modulus of FRC implant can be matched with local requirements. This study tested the in vivo performance of novel FRC implants made of unidirectional glass fibers (E-glass fibers in Bis-GMA and TEGDMA polymeric matrix). The implant surface was covered with bioactive glass granules. Control implants were made of surface-roughened titanium. Stress-shielding effects of the implants were predicted by finite element modelling (FEM). Surgical stabilization of bone metastasis in the subtrochanteric region of the femur was simulated in 12 rabbits. An oblong subtrochanteric defect of a standardized size (reducing the torsional strength of the bones approximately by 66%) was created and an intramedullary implant made of titanium or the FRC composite was inserted. The contralateral femur served as the intact control. At 12 weeks of healing, the femurs were harvested and analyzed by radiography, torsional testing, micro-CT imaging and hard tissue histology. The functional recovery was unremarkable in both groups, although the final analysis revealed two healed undisplaced peri-implant fractures in the group of FRC implants. FEM studies demonstrated differences in stress-shielding effects of the titanium and FRC implants, but the expected biological consequences did not become evident during the follow-up time of the animal study. Biomechanical testing of the retrieved femurs showed no significant differences between the groups. The torsional strength of the fixed bones had returned the level of contralateral intact femurs. Both implants showed ongrowth of intramedullary new bone. No adverse tissue reactions were observed. Based on these favorable results, a large-scale EU-project (NewBone, www.hb.se/ih/polymer/newbone) has been launched for development of orthopaedic FRC implants.

Fixation and bone remodeling around a low stiffness stem in revision surgery

Femoral stems with reduced stiffness have the potential of decreasing stress shielding and could be an alternative in revision surgery when restoration of bone stock is required. We retrospectively reviewed 38 patients (40 stems) with a central core of cobalt-chromium surrounded by a polymer and an outer titanium mesh layer containing a proximal coating of hydroxyapatite/tricalcium phosphate; 30 of the 38 patients (32 hips) had a minimum 2-year followup. We impacted morselized allograft around the stem in 28 of 32 revisions. Repeated radiostereometric examinations showed medial, distal, and posterior migration (median, 0.21 mm, 0.17 mm, and 0.96 mm, respectively) of the femoral head center for up to 6 months followed by stabilization. Measurements of bone mineral density in the seven Gruen zones at 6 months revealed either a decrease (down to a median of 3%), no change, or a slight increase (up to 5%) followed by a further increase up to 2 years in three of the regions (2, 3, and 5). Conventional radiography at 2 years demonstrated graft remodeling and incomplete radiolucent lines in 19 hips, mainly in Regions 1 and 7. Two hips were reoperated on as a result of dislocation, but none of the stems had been revised.

LEVEL OF EVIDENCE

Level IV, therapeutic study. See the Guidelines for Authors for a complete description of levels of evidence.

PEEK biomaterials in trauma, orthopedic, and spinal implants

Since the 1980s, polyaryletherketones (PAEKs) have been increasingly employed as biomaterials for trauma, orthopedic, and spinal implants. We have synthesized the extensive polymer science literature as it relates to structure, mechanical properties, and chemical resistance of PAEK biomaterials. With this foundation, one can more readily appreciate why this family of polymers will be inherently strong, inert, and biocompatible. Due to its relative inertness, PEEK biomaterials are an attractive platform upon which to develop novel bioactive materials, and some steps have already been taken in that direction, with the blending of HA and TCP into sintered PEEK. However, to date, blended HA-PEEK composites have involved a trade-off in mechanical properties in exchange for their increased bioactivity. PEEK has had the greatest clinical impact in the field of spine implant design, and PEEK is now broadly accepted as a radiolucent alternative to metallic biomaterials in the spine community. For mature fields, such as total joint replacements and fracture fixation implants, radiolucency is an attractive but not necessarily critical material feature.