Wear Distribution Detection of Knee Joint Prostheses by Means of 3D Optical Scanners

Linear and Volumetric Polyethylene Wear Patterns after Primary Cruciate-Retaining Total Knee Arthroplasty Failure: An Analysis Using Optical Scanning and Computer-Aided Design Models

(1) Background: Analyses of retrieved inserts allow for a better understanding of TKA failure mechanisms and the detection of factors that cause increased wear. The purpose of this implant retrieval study was to identify whether insert volumetric wear significantly differs among groups of common causes of total knee arthroplasty failure, whether there is a characteristic wear distribution pattern for a common cause of failure, and whether nominal insert size and component size ratio (femur-to-insert) influence linear and volumetric wear rates. (2) Methods: We digitally reconstructed 59 retrieved single-model cruciate-retaining inserts and computed their articular load-bearing surface wear utilizing an optical scanner and computer-aided design models as references. After comprehensively reviewing all cases, each was categorized into one or more of the following groups: prosthetic joint infection, osteolysis, clinical loosening of the component, joint malalignment or component malposition, instability, and other isolated causes. The associations between volumetric wear and causes of failure were estimated using a multiple linear regression model adjusted for time in situ. Insert linear penetration wear maps from the respective groups of failure were further processed and merged to create a single average binary image, highlighting a potential wear distribution pattern. The differences in wear rates according to nominal insert size (small vs. medium vs. large) and component size ratio (≤1 vs. >1) were tested using the Kruskal-Wallis test and the Mann-Whitney test, respectively. (3) Results: Patients with identified osteolysis alone and those also with clinical loosening of the component had significantly higher volumetric wear when compared to those without both causes (p = 0.016 and p = 0.009, respectively). All other causes were not significantly associated with volumetric wear. The instability group differentiated from the others with a combined peripheral antero-posterior wear distribution. Linear and volumetric wear rates showed no significant differences when compared by nominal insert size (small vs. medium vs. large, p = 0.563 and p = 0.747, respectively) or by component (femoral-to-insert) size ratio (≤1 vs. >1, p = 0.885 and p = 0.055, respectively). (4) Conclusions: The study found increased volumetric wear in cases of osteolysis alone, with greater wear when combined with clinical loosening compared to other groups. The instability group demonstrated a characteristic peripheral anterior and posterior wear pattern. Insert size and component size ratio seem not to influence wear rates.

Development of a Three-Dimensional Optical Verification Technology without Environmental Pollution for Metal Components with Different Surface Properties

Nowadays, the optical measuring approach is widely used in the precision machining industry due to high measurement efficiency. In the industry, measuring devices play a crucial role in the field of quality assurance. In practical engineering, the green measurement approach indeed plays an important role in the industry currently. In this study, a state-of-the-art green technique for three-dimensional (3D) optical measurements without environmental pollution is demonstrated, which is an environmentally friendly optical measurement method. This method can perform precise optical measurement without matte coatings. This work dealt with the possibility of measuring four metal components that were not sprayed with anything. The differences in the optical measurement results between with and without matte coatings were investigated and analyzed. It was found that the research result has practical value in the precision machining industry because average size errors of the four measurement objects with different surface properties can be controlled at about 3 µm, 0.1 µm, 0.5 µm, and 9 µm. A technical database with industrial value was established for optical measurements of metal components with different surface properties without matte coatings, which can serve as an alternative to the conventional 3D optical measurement.

In vitro method to quantify and visualize mechanical wear in human meniscus subjected to joint loading

The mechanical wear and tear of soft connective tissue from repetitive joint loading is a primary factor in degenerative joint disease, and therefore methods are needed to accurately characterize wear in joint structures. Here, we evaluate the accuracy of using a structured light 3D optical scanning system and modeling software to quantify and visualize volume loss in whole human meniscus subjected to in vitro joint loading. Using 3D printed meniscus replicas with known wear volumes, we determined that this novel imaging method has a mean accuracy of approximately 13 mm3, corresponding to a mean error of less than 7% when measuring meniscal volumetric changes of 0.2 cm3 (size of a pea). The imaging method was then applied to measure the in vitro wear of whole human menisci at four time points when a single cadaveric knee was subjected to one million cycles of controlled joint loading. The medial and lateral menisci reached steady state volumetric reductions of 0.72 cm3 and 0.34 cm3 per million cycles, respectively. Colorimetric maps of linear wear depth revealed high wear and deformation in the posterior regions of both the medial and lateral menisci. For the first time, this study has developed a method to accurately characterize volume loss in whole meniscus subjected to in vitro joint loading. This 3D scanning method offers researchers a new investigative tool to study mechanical wear and joint degeneration in meniscus, and other soft connective tissues.

An Environmentally-Friendly Three-Dimensional Computer-Aided Verification Technique for Plastic Parts

Plastic components play a significant role in conserving and saving energy. Plastic products provide some advantages over metal, including reducing part weight, manufacturing costs, and waste, and increasing corrosion resistance. Environmental sustainability is one of the sustainable development goals (SDGs). Currently, the non-contact computer-aided verification method is frequently employed in the plastic industry due to its high measurement efficiency compared with the conventional contact measuring method. In this study, we proposed an innovative, green three-dimensional (3D) optical inspection technology, which can perform precise 3D optical inspection without spraying anything on the component surface. We carried out the feasibility experiments using two plastic parts with complex geometric shapes under eight different proposed measurement strategies that can be adjusted according to the software interface. We studied and analyzed the differences in 3D optical inspection for building an empirical technical database. Our aim in this study is to propose a technical database for 3D optical measurements of an object without spraying anything to the component’s surface. We found that the research results fulfilled the requirements of the SDGs. Our research results have industrial applicability and practical value because the dimensional average error of the two plastic parts has been controlled at approximately 3 µm and 4.7 µm.

Wear and performance of a tripolar total hip replacement

Background

An unconstrained tripolar hip replacement matches a large capacity two-piece metal/polyethylene acetabular component with a bipolar prosthesis. This combination of accepted technology is different than the relatively new dual mobility prosthesis. The goal is to protect against dislocation and allow close to a normal range of motion (ROM). So far there has not been enough information about wear and performance of tripolar hip replacement to support its wide use.

Methods

Twenty-four tripolar prostheses were retrieved from 23 patients after a mean of 14 years (range, 5-21 years). All implants had been placed in high-demand patients who participated in adventure sports, had occupations where a dislocation would be dangerous, or in patients undergoing revision. The tripolar prosthesis has three important design features: (I) the acetabular component uses highly cross-linked polyethylene with an internal diameter of 41-54 mm, (II) the bipolar is titanium nitride-coated, and (III) the bipolar prosthesis has positive eccentricity. The retrievals were evaluated for wear, performance, and mechanical function.

Results

The total volumetric wear was 24 mm3/yr. compared to 54 mm3/yr. For a dual mobility prosthesis and 38 mm3/yr. for a 40 mm conventional hip replacement. The jump distance was 16 mm compared to 12 mm for a 36 mm hip replacement. There was no osteolysis. The combined flexion/extension was 145 compared to 119 for a conventional prosthesis. The mean UCLA score was 7.9. Radiographs showed continued shared movement between the inner and outer articulations. The prosthetic bipolar separation force was 2,180 N. High-demand activities generate approximately 340 N.

Conclusions

The wear of this tripolar hip prosthesis is low below the osteolytic threshold. The increased ROM and increased jump distance provide the most stable unconstrained hip replacement available. The wear and mechanical performance seen in this study suggest a lifetime of use is possible in even the highest demand patients. The absence of intraprosthetic dislocation, metal wear reaction, and limited acetabular stress shielding make this a safer technology compared to a dual mobility prosthesis.

Manufacture and mechanical properties of knee implants using SWCNTs/UHMWPE composites

This article focuses on obtaining ultra high molecular weight polyethylene (UHMWPE) material reinforced with functionalized single-walled carbon nanotubes (f-SWCNTs) and the manufacturing of unicompartmental knee implants via Single-Point Incremental Forming process (SPIF). The physicochemical properties of the developed UHMWPE reinforced with 0.01 and 0.1 wt% concentrations of f-SWCNTs are investigated using Raman and Thermogravimetic Analysis (TGA). Tensile mechanical tests performed in the nanocomposite material samples reveal a 12% improvement in their Young's modulus when compare to that of the pure UHMWPE material samples. Furthermore, the surface biocompatibility of the UHMWPE reinforced with f-SWCNTs materials samples was evaluated with human osteoblast cells. Results show cell viability enhancement with good cell growth and differentiation after 14 incubation days, that validates the usefulness of the developed nanocomposite material in the production of hip and knee artificial implants, and other biomedical applications.

A Perspective on Biotribology in Arthroplasty: From In Vitro toward the Accurate In Silico Wear Prediction

Nowadays hip arthroplasty is recognized as one of the most successful orthopedic surgical procedures, even if it involves challenges to overcome, such that lately, younger and more active patients are in need of total arthroplasty. Wear is still one of the main issues affecting joint prostheses endurance, and often causes loosening accompanied by implant failures. Actual in vitro wear tests executed by mechanical simulators have a long duration, are very expensive, and do not take into account all the possible daily activities of the patients; thus, the challenge to obtain a complete in silico tribological and dynamical model of (bio) tribo-systems could give the possibility to overcome the actual testing procedures and could contribute as a tool for a more accurate tribological design of human prostheses. This prospective paper is intended to underline actual research trends toward the challenge of having accurate numerical algorithms to be used both in preclinical testing and in the optimizations of the prostheses design. With this aim we depicted the possible in silico approach in artificial joints’ wear assessment over time, accounting for contact mechanics, numerical stress–strain analysis, musculoskeletal multibody, and synovial lubrication modelling (boundary/mixed, hydrodynamic, and elastohydrodynamic).

New Instrumented Trolleys and A Procedure for Automatic 3D Optical Inspection of Railways

This paper focuses on new instrumented trolleys, allowing automated 3D inspection of railway infrastructures, using optical scanning principles and devices for defects and damage evaluation. Inspection of rolling components is crucial for wear evaluation and to schedule maintenance interventions to assure safety. Currently, inspection trolleys are mainly instrumented with 2D contact or optical sensors. The application of 3D non-contact digitizers proposed in this paper allows for a quick and more complete monitoring of the health conditions of railways, also in combination with a proper procedure for automatic 3D inspection. The results of the experimental tests using 3D portable optical scanners on railways are compared with results obtained by a trolley instrumented with 2D contact sensors. The results demonstrate the effectiveness of the trolleys mounting 3D handheld optical digitizers with proper automated software inspection procedures.

Knee Wear Assessment: 3D Scanners Used as a Consolidated Procedure

It is well known that wear occurring in polyethylene menisci is a significant clinical problem. At this regard, wear tests on biomaterials medical devices are performed in order to assess their pre-clinical performance in terms of wear, durability, resistance to fatigue, etc. The objective of this study was to assess the wear of mobile total knee polyethylene inserts after an in vitro wear test. In particular, the wear behavior of mobile bearing polyethylene knee configurations was investigated using a knee joint wear simulator. After the completion of the wear test, the polyethylene mobile menisci were analyzed through a consolidated procedure by using 3D optical scanners, in order to evaluate the 3D wear distribution on the prosthesis surface, wear depths, wear rates, amount of material loss and contact areas. The results in terms of wear rates and wear volumes were compared with results of gravimetric tests, finding equivalent achievements.

Advances in Optomechatronics: An Automated Tilt-Rotational 3D Scanner for High-Quality Reconstructions

3D vision systems are more and more required in a large variety of applications and mostly for mechanical and medical purposes. This paper presents the study and realization of a prototype of a structured light automated tilt-rotational 3D vision system for high-quality reconstructions of components of various sizes and in cases of freeform and complex surfaces. The main goal of this research work was to develop an instrument with the following main novelties: configurability for different object sizes, high precision and resolution levels and ability to automatically generate the mesh representing the full scanned objects without any intervention of the operator by means of a 2 degrees of freedom automated tilt-rotational mechanical positioning system. A detailed analysis of the instrument and the procedures and results of the performance tests are presented, together with the examination of possible strategies to obtain a better performance, especially by the calibration and the synchronization between the optical and the mechanical systems. As a result, the prototype and the performance parameters resulting from the experimental campaigns, are reported.

Development of a Novel in Silico Model to Investigate the Influence of Radial Clearance on the Acetabular Cup Contact Pressure in Hip Implants

A hip joint replacement is considered one of the most successful orthopedic surgical procedures although it involves challenges that must be overcome. The patient group undergoing total hip arthroplasty now includes younger and more active patients who require a broad range of motion and a longer service lifetime of the implant. The current replacement joint results are not fully satisfactory for these patients' demands. As particle release is one of the main issues, pre-clinical experimental wear testing of total hip replacement components is an invaluable tool for evaluating new implant designs and materials. The aim of the study was to investigate the cup tensional state by varying the clearance between head and cup. For doing this we use a novel hard-on-soft finite element model with kinematic and dynamic conditions calculated from a musculoskeletal multibody model during the gait. Four different usual radial clearances were considered, ranging from 0 to 0.5 mm. The results showed that radial clearance plays a key role in acetabular cup stress-strain during the gait, showing from the 0 value to the highest, 0.5, a difference of 44% and 35% in terms of maximum pressure and deformation, respectively. Moreover, the presented model could be usefully exploited for complete elastohydrodynamic synovial lubrication modelling of the joint, with the aim of moving towards an increasingly realistic total hip arthroplasty in silico wear assessment accounting for differences in radial clearances.

Quantifying wear depth in hip prostheses using a 3D optical scanner

The visualization of wear depth in hip prostheses can assist the evaluation of new bearing materials and implant designs. The goal of this study was to develop an accurate, fast, and economical methodology to generate colorimetric maps of wear depth in hip implants using a structured light 3D optical scanning system. The accuracy and precision of this novel technique were determined using reference blocks with known wear depths. This technique was then used to measure the in vitro wear of a hip resurfacing device for canines that incorporates a highly cross-linked polyethylene liner. The 3D optical scanner had an average accuracy of 2.1 µm and an average precision of 1.4 µm, which corresponded to errors less than 10% when measuring wear depths of 20 µm or greater. The scanner was able to repeatedly generate 3D colorimetric maps of wear depth in highly cross-linked polyethylene liners in 20 min or less. These colorimetric maps identified localized regions with 3-fold greater wear than the average wear depth, and revealed liners with asymmetric wear patterns. For the first time, this study has validated the use of 3D optical scanning to quantify in vitro surface wear in a hip replacement device.

Method for measuring wear on boot outsoles using a 3D laser scanner

In the mining industry, slips and falls are the second leading cause of non-fatal injuries. Footwear is the primary defence against a slip; consequently, the condition of the footwear outsole is critical to maintaining slip resistance. Currently, there is no published method that can be used to determine when the outsole no longer affords adequate slip protection. Moreover, quantifying the condition of the outsole through the measurement of outsole features can be tedious. This article introduces a new method for the quantification of boot outsole wear. Using a handheld 3D scanner, boot scans can be taken quickly and the developed models used to measure outsole features. This method also accounts for the bending of the boot due to normal wear, which may otherwise introduce erroneous measures. When compared to measurements with a traditional handheld calliper, this new method offers more flexibility in terms of data collection, accounts for other types of boot transformations, and is more efficient to use over multiple measurement periods with no statistically significant differences in measurement.

New Challenges in Tribology: Wear Assessment Using 3D Optical Scanners

Wear is a significant mechanical and clinical problem. To acquire further knowledge on the tribological phenomena that involve freeform mechanical components or medical prostheses, wear tests are performed on biomedical and industrial materials in order to solve or reduce failures or malfunctions due to material loss. Scientific and technological advances in the field of optical scanning allow the application of innovative devices for wear measurements, leading to improvements that were unimaginable until a few years ago. It is therefore important to develop techniques, based on new instrumentations, for more accurate and reproducible measurements of wear. The aim of this work is to discuss the use of innovative 3D optical scanners and an experimental procedure to detect and evaluate wear, comparing this technique with other wear evaluation methods for industrial components and biomedical devices.