Experimental evaluation of a new morphological approximation of the articular surfaces of the ankle joint

An overview of 3D printed metal implants in orthopedic applications: Present and future perspectives

With the ability to produce components with complex and precise structures, additive manufacturing or 3D printing techniques are now widely applied in both industry and consumer markets. The emergence of tissue engineering has facilitated the application of 3D printing in the field of biomedical implants. 3D printed implants with proper structural design can not only eliminate the stress shielding effect but also improve in vivo biocompatibility and functionality. By combining medical images derived from technologies such as X-ray scanning, CT, MRI, or ultrasonic scanning, 3D printing can be used to create patient-specific implants with almost the same anatomical structures as the injured tissues. Numerous clinical trials have already been conducted with customized implants. However, the limited availability of raw materials for printing and a lack of guidance from related regulations or laws may impede the development of 3D printing in medical implants. This review provides information on the current state of 3D printing techniques in orthopedic implant applications. The current challenges and future perspectives are also included.

Total Ankle Replacement: Biomechanics of the Designs, Clinical Outcomes, and Remaining Issues

The present review paper aimed at discussing the current major issues in total ankle replacement, both the technical and biomechanical concepts, and the surgical and clinical concerns. Designers shall target at the same time restoration of natural ankle kinematics and congruity of the artificial surfaces throughout the range of motion. Surgeons are recommended to expand biomechanical knowledge on ankle joint replacement, and provide appropriate training and key factors to make arthroplasty a good alternative to arthrodesis. Moreover, adequate selection of patients and careful rehabilitation are critical. In the future, custom-made prosthesis components and patient-specific instrumentation are major developments for more complex cases.

Articular geometry can affect joint kinematics, contact mechanics, and implant-bone micromotion in total ankle arthroplasty

Implant loosening and bearing surface wear remain the most common failure problems of total ankle arthroplasty (TAA). One of the main factors leading to these problems is the nonphysiologic design of articular surfaces. The goals of this study were to reveal the effects of the anatomical medial-lateral borders height differences, coronal and sagittal radii on the joint kinematics, contact mechanics, and implant-bone micromotion in TAA. A previously developed and validated musculoskeletal (MSK) multibody dynamics (MBD) modeling method of TAA based on AnyBody generic MSK MBD model (five simulations for each implant) was used by combining with a finite element analysis. Five ankle implant models with different articular surface morphologies were created according to the anatomic characteristics of Chinese measurement data, marked as Implant A to E. The total ankle forces and motions during walking simulation were predicted by MSK MBD models and the contact mechanics of the bearing surface and the micromotion of the implant-bone interface of TAA were predicted by FE models. Compared with Implant A, the internal-external rotation in Implant E increased by 12.14%, the maximum of anterior-posterior translation in Implant E increased by 5.62%, the maximum reduction of tibial micromotion in Implant E was 59.98%, and for talar, micromotion was 15.36%. The ankle implant with similar anatomic articular surface has the potential to allow patients to recover better motions and reduce the risk of early loosening. This study would provide design guidance for the development of new ankle implants and further advance the development of TAA. Clinical Significance: This study promoted the improvement of ankle implant design and made contributions to improve the service life of ankle implant and patient satisfaction.

Comparison of joint load, motions and contact stress and bone-implant interface micromotion of three implant designs for total ankle arthroplasty

BACKGROUND AND OBJECTIVE

Loosening and wear are still the main problems for the failure of total ankle arthroplasty, which are closely related to the micromotion at the bone-implant interface and the contact stress and joint motions at the articular surfaces. Implant design is a key factor to influence the ankle force, motions, contact stress, and bone-implant interface micromotion. The purpose of this study is to evaluate the differences in these parameters of INBONE II, INFINITY, and a new anatomic ankle implant under the physiological walking gait of three patients.

METHODS

This was achieved by using an in-silico simulation framework combining patient-specific musculoskeletal multibody dynamics and finite element analysis. Each implant was implanted into the musculoskeletal multibody dynamics model, respectively, which was driven by the gait data to calculate ankle forces and motions. These were then used as the boundary conditions for the finite element model, and the contact stress and the bone-implant interface micromotions were calculated.

RESULTS

The total ankle contact forces were not significantly affected by articular surface geometries of ankle implants. The range of motion of the ankle joint implanted with INFINITY was a little larger than that with INBONE II. The anatomic ankle implant design produced a greater range of motion than INBONE II, especially the internal-external rotation. The fixation design of INFINITY achieved lower bone-implant interface micromotion compared with INBONE II. The anatomic ankle implant design produced smaller contact stress with no evident edge contact and a smaller tibia-implant interface micromotion. In addition, significant differences in the magnitudes and tendencies of total ankle contact forces and motions among different patients were found.

CONCLUSIONS

The articular surface geometry of ankle implants not only affected the ankle motions and contact stress distribution but also affected the bone-implant interface micromotions. The anatomic ankle implant had good performance in recovering ankle joint motion, equalizing contact stress, and reducing bone-implant interface micromotion. INFINITY's fixation design could achieve smaller bone-implant interface micromotion than INBONE II.

Effect of Ligament Mapping from Different Magnetic Resonance Image Quality on Joint Stability in a Personalized Dynamic Model of the Human Ankle Complex

Background. Mechanical models of the human ankle complex are used to study the stabilizing role of ligaments. Identification of ligament function may be improved via image-based personalized approach. The aim of this study is to compare the effect of the ligament origin and insertion site definitions obtained with different magnetic resonance imaging (MRI) modalities on the mechanical behaviour of a dynamic model of the ankle complex. Methods. MRI scans, both via 1.5 T and 3.0 T, were performed on a lower-limb specimen, free from anatomical defects, to obtain morphological information on ligament-to-bone attachment sites. This specimen was used previously to develop the dynamic model. A third ligament attachment site mapping scheme was based on anatomical dissection of the scanned specimen. Following morphological comparison of the ligament attachment sites, their effect on the mechanical behaviour of the ankle complex, expressed by three-dimensional load–displacement properties, was assessed through the model. Results. Large differences were observed in the subtalar ligament attachment sites between those obtained through the two MRI scanning modalities. The 3.0 T MRI mapping was more consistent with dissection than the 1.5 T MRI. Load–displacement curves showed similar mechanical behaviours between the three mappings in the frontal plane, but those obtained from the 3.0 T MRI mapping were closer to those obtained from dissection. Conclusions. The state-of-the-art 3.0 T MRI image analysis resulted in more realistic mapping of ligament fibre origin and insertion site definitions; corresponding load–displacement predictions from a subject-specific model of the ankle complex showed a mechanical behaviour more similar to that using direct ligament attachment observations.

Shape Approximation and Size Difference of the Upper Part of the Talus: Implication for Implant Design of the Talar Component for Total Ankle Replacement

The implant design of the talar component for total ankle replacement (TAR) should match the surface morphology of the talus so that the replaced ankle can restore the natural motion of the tibiotalar joint and may reduce postoperative complications. The purpose of this study was to introduce a new 3D fitting method (the two-sphere fitting method of the talar trochlea with three fitting resection planes) to approximate the shape of the upper part of the talus for the Chinese population. 90 models of the tali from CT images of healthy volunteers were used in this study. Geometrical fitting and morphological measurements were performed for the surface morphology of the upper part of the talus. The accuracy of the two-sphere fitting method of the talar trochlea was assessed by a comparison of previously reported data. Parameters of the fitting geometries with different sizes were recorded and compared. Results showed that compared with previously reported one-sphere, cylinder, and bitruncated cone fitting methods, the two-sphere fitting method presented the smallest maximum distance difference, indicating that talar trochlea can be approximated well as two spheres. The radius of the medial fitting sphere $R_M$ was $20.69\pm 2.19$  mm which was significantly smaller than the radius of the lateral fitting sphere $R_L$ of $21.32\pm 1.88$  mm. After grouping all data by the average radius of fitting spheres, the result showed that different sizes of the upper part of the talus presented significantly different parameters except the orientation of the lateral cutting plane, indicating that the orientation of the lateral cutting plane may keep consistent for all upper part of the talus and have no relationship with the size. The linear regression analyses demonstrated a weak correlation ( $R^2<0.5$ ) between the majority of parameters and the average radius of the fitting spheres. Therefore, different sizes of the upper part of the talus presented unique morphological features, and the design of different sizes of talar components for TAR should consider the size-specific characteristics of the talus. The parameters measured in this study provided a further understanding of the talus and can guide the design of different sizes of the talar components of the TAR implant.

The effect of osteochondral lesion size and ankle joint position on cartilage behavior - numerical and in vitro experimental results

Osteochondral lesion of the talus is defined as damage in the cartilage that covers the talus bone, compromising the integrity of the joint in the long term. Due to the low incidence of this pathology, there are few studies to understand the importance of lesion size and position in cartilage strains. The purpose of this study is then to analyze the influence of the lesion size in joint behavior. A 3D virtual and in vitro model of a patient's injured ankle joint was developed. The models were built using CT scan and MRI images, to obtain the CAD models of intact and with 10 mm lesion size for 3D print models using additive manufacturing. The physical model was tested with 685N applied vertically to determine experimentally the principal strains and contact pressures in the cartilage. Five finite element models were developed with lesion dimensions (5 to 20 mm) and with 3 ankle joint positions. The numerical and experimental results were correlated with an R² = 0.86 justified by the complexity of the model geometry. The maximum principal strain was 2566µε in the plantar flexion position without lesion. The experimental contact area between cartilages increased by 1.2% in the 10 mm lesion size for 431 mm². The maximum stress in the cartilage was observed for a 20 mm lesion size with 2.5 MPa. The 5 and 10 mm sizes present similar results; the 15 mm lesion size presents a stress increase of 13% comparatively with 10 mm. Plantar flexion seems to be the most critical configuration; stress increases with an increase of lesion size around the cartilage.

Effect of artificial surface shapes and their malpositioning on the mechanics of the replaced ankle joint for possible better prosthesis designs

BACKGROUND

The clinical outcomes of total ankle replacement are limited by prosthesis component malpositioning during surgery. The goal of this study is to assess the mechanical impact of this malpositioning in a validated computer model.

METHODS

In a previously developed multi-body dynamic model of the human ankle complex three different artificial implants were designed, each one presenting a different approximation of the natural articular surfaces of the corresponding specimen. The most common implant translational and rotational malpositionings were defined and mimicked. Dynamic simulations of joint motion were run for the various surfaces and malpositionings. The same input loading conditions derived from a previous in-vitro experiment on the corresponding natural specimen were applied.

FINDINGS

From load-displacement graphs it was observed that all three artificial surfaces reproduced well physiological motion between the calcaneus and the tibia/fibula, with a maximum difference of 2°. It was found that antero-posterior translation of either the tibial or the talar component and inclination of the tibial component in the sagittal plane led to considerable increases in the range of motion. Antero-posterior and dorsiflexion of the tibial component resulted in an increased internal-external rotation by up to 3.5° and 4.0°, respectively. The corresponding increase of inversion-eversion was 5.0° and 6.5°.

INTERPRETATION

This study showed that relatively small surgical errors have great consequences in replaced joint mechanics. The present model can be used in future studies to analyse the effect of malpositioning with any specific current total ankle prosthesis.

Estimating the stabilizing function of ankle and subtalar ligaments via a morphology-specific three-dimensional dynamic model

Knowledge of the stabilizing role of the ankle and subtalar ligaments is important for improving clinical techniques such as ligament repair and reconstruction. However, this knowledge is incomplete. The goal of this study was to expand this knowledge by investigating the stabilizing function of the ligaments using multiple morphologically subject-specific computational models. Nine models were created from the lower extremities of nine donors. Each model consisted of the articulating bones, articular cartilage, and ligaments. Simulations were conducted in ADAMS™ - a dynamic simulation program. During simulation, tibia and fibula were fixed while cyclic moments in all three anatomical planes were applied to the calcaneus one-at-a-time. The resulting displacements between the bones and the forces in each ligament were computed. Simulations were conducted with all ligaments intact and after simulated ligament serial sectioning. Each model was validated by comparing the simulation results to experimental data obtained from the specimen used to construct the model. From the results the stabilizing role of each ligament was established and the effect of ligament sectioning on Range of Motion and Overall Laxity was identified. On the lateral side, ATFL provided stabilization in supination, CFL restrained inversion, external rotation and dorsiflexion and PTFL limited dorsiflexion and external rotation. On the medial side, PTTL restrained dorsiflexion and internal rotation, ATTL limited plantarflexion and external rotation, and TCL limited dorsiflexion, eversion and external rotation. At the subtalar joint, ITCL limited plantarflexion and its posterior-lateral bundle restrained subtalar inversion. CL restrained plantarflexion/dorsiflexion, and internal and external rotation. The large inter-model variability observed in the results indicate the importance of using multiple subject-specific models rather than relying on one "representative" model.

Assessing mechanical ankle instability via functional 3D stress-MRI - A pilot study

BACKGROUND

Quantitative measurement of the mechanical deficit in chronic ankle instability (CAI) is difficult. Therefore, the distinction between functional (FAI) and mechanical ankle instability (MAI) as well as the evaluation of surgical techniques is difficult. This pilot study uses a novel method of functional 3-dimensional stress ankle-MRI to test its applicability for assessing mechanical ankle instability.

METHODS

We used a custom-built ankle arthrometer that allows a stepless positioning of the foot and an axial in situ loading with up to 500 N combined with a 3-dimensional MRI protocol. We assessed four parameters (3D cartilage contact area (CCA) fibulotalar, tibiotalar horizontal and vertical and intermalleolar distance) under six different conditions (neutral-null, plantarflexion-supination and dorsiflexion-pronation each with and without loading) in n = 10 individuals (7 suffering from MAI and 3 healthy controls).

FINDINGS

The MAI group showed a substantially increased reduction of lateral osseous constraint compared to healthy controls when the foot was positioned in plantarflexion-supination (CCA fibulotalar 69% vs. 30% in controls). The reduction of the weight bearing surface in plantarflexion-supination was also more pronounced (CCA tibiotalar horizontal -49% in MAI vs. -28% in controls).

INTERPRETATION

This novel technique is valuable for assessing mechanical ankle instability in the target population and has a potential clinical benefit for assessing the mechanical deficit of individual patients. Further studies are needed to provide evidence for a possible prognostic value of this novel technique.

Talar Dome Investigation and Talocrural Joint Axis Analysis Based on Three-Dimensional (3D) Models: Implications for Prosthetic Design

Ankle joint kinematics is mainly stabilized by the morphology of the talar dome and the articular surface of tibiofibular mortise as well as the medial and lateral ligament complexes. Because of this the bicondylar geometry of talus dome is believed to be crucial for ankle implant design. However, little data exist describing the precise anatomy of the talar dome and the talocrural joint axis. The aim of this study is to document the anatomy of the talar dome and the axis of the talocrural joint using three-dimensional (3D) computed tomographic (CT) modeling. Seventy-one participants enrolled for CT scanning and 3D talar model reconstruction. All the ankles were held in a neutral position during the CT scanning. Six points on the lateral and medial crest of the talar dome were defined. The coordinate of the six points; radii of lateral-anterior (R-LA), lateral-posterior (R-LP), medial-anterior (R-MA), and medial-posterior (R-MP) sections; and inclination angle of the talar dome were measured, and the inclination and deviation angles of the talocrural joint axis were determined. The mean values of R-LA, R-LP, R-MA, and R-MP were 19.23 ± 2.47 mm, 18.76 ± 2.90 mm, 17.02 ± 3.49 mm, and 22.75 ± 3.04 mm. The mean inclination angle of the talar dome was 9.86 ± 3.30 degrees. Gender variation was found in this parameter. The mean inclination and deviation angles were 8.60 ± 0.07 and 0.76 ± 0.69 degrees for the dorsiflexion axis and −7.34 ± 0.07 and 0.09 ± 0.18 degrees for the plantarflexion axis. Bilateral asymmetries between the medial and lateral crest of the talar dome were found, which resulted in different dorsiflexion and plantarflexion axes of the talocrural joint. Currently, no ankle implants replicate this talar anatomy, and these findings should be considered in future implant designs.

Comparison of cartilage and bone morphological models of the ankle joint derived from different medical imaging technologies

Background

Accurate geometrical models of bones and cartilage are necessary in biomechanical modelling of human joints, and in planning and designing of joint replacements. Image-based subject-specific model development requires image segmentation, spatial filtering and 3-dimensional rendering. This is usually based on computed tomography (CT) for bone models, on magnetic resonance imaging (MRI) for cartilage models. This process has been reported extensively in the past, but no studies have ever compared the accuracy and quality of these models when obtained also by merging different imaging modalities. The scope of the present work is to provide this comparative analysis in order to identify optimal imaging modality and registration techniques for producing 3-dimensional bone and cartilage models of the ankle joint.

Methods

One cadaveric leg was instrumented with multimodal markers and scanned using five different imaging modalities: a standard, a dual-energy and a cone-beam CT (CBCT) device, and a 1.5 and 3.0 Tesla MRI devices. Bone, cartilage, and combined bone and cartilage models were produced from each of these imaging modalities, and registered in space according to matching model surfaces or to corresponding marker centres. To assess the quality in overall model reconstruction, distance map analyses were performed and the difference between model surfaces obtained from the different imaging modalities and registration techniques was measured.

Results

The registration between models worked better with model surface matching than corresponding marker positions, particularly with MRI. The best bone models were obtained with the CBCT. Models with cartilage were defined better with the 3.0 Tesla than the 1.5 Tesla. For the combined bone and cartilage models, the colour maps and the numerical results from distance map analysis (DMA) showed that the smallest distances and the largest homogeneity were obtained from the CBCT and the 3.0 T MRI via model surface registration.

Conclusions

These observations are important in producing accurate bone and cartilage models from medical imaging and relevant for applications such as designing of custom-made ankle replacements or, more in general, of implants for total as well as focal joint replacements.

Development of a simplified, reproducible, parametric 3D model of the talus

Computational foot models have significant application in surgical decision making, injury and disease diagnosis and prevention, sports performance analysis and footwear engineering. However, due to the substantial time in model building and the heavy computational costs from the complexity of the models, daily clinical application of these foot models has yet to be achieved. Much of the previous research adopted a detailed-geometry approach in modeling bones that potentially contributed to the heavy computational costs. In this research, we developed a computational talus model based on CT section image data, image reconstruction and segmentation, contact surface identification, standard shape fitting, and finite element auto meshing algorithms. Modeling the bones as rigid is common, and modeling the contact surfaces only for the rigid body saves additional computational resources. Priority, therefore, in the shape fitting with optimization is given to the contact surfaces of the talus. Thirteen sets (9 males and 4 females) of CT section data were obtained. Image reconstruction, segmentation and bone labeling were conducted on each set of CT data to identify talus and its adjacent bones. Contact surfaces of the talus were then identified based on bone spatial relationships. Apart from the talar dome surface which was fitted by a 3rd-order polynomial, standard shapes such as ellipsoids and planes were used to fit the selected contact surfaces so that the geometrical parameters maintain physical significance. Based on these parameters, we automatically recreated and meshed the least-squares fitted shapes rapidly with limited elements. Last, mean major contact surfaces of the talus were obtained and fitted by standard shapes. Although the number of samples in this study was relatively small, our method provides sufficient and accurate geometric parameters of these contact surfaces to completely describe and reproduce the talus, on both a subject specific and average basis. The method for describing the talus here helps to parametrize computational models using planes and ellipsoids, improves surgical decision making and implants with a more precise and physically significant measures, and the description provides bone geometric parameters which can later be used to relate risk analysis for bone shape specific injury rates.

New comprehensive procedure for custom-made total ankle replacements: Medical imaging, joint modeling, prosthesis design, and 3D printing

Many failures in total joint replacement are associated to prosthesis-to-bone mismatch. With recent additive-manufacturing, that is, 3D-printing, custom-made prosthesis can be created by laser-melting metal powders layer-by-layer. Ankle replacement is particularly suitable for this progress because of the limited number of sizes and the poor bone stock. In this study a novel procedure is presented for subject-specific ankle replacements, including medical-imaging, joint modelling, prosthesis design, and 3D-printing. Three shank-foot specimens were CT-scanned, and corresponding 3D bone models of the tibia, fibula, talus, and calcaneus were obtained. From these models, specimen-specific implant sets were designed according to three different concepts, and 3D-printed from cobalt-chromium-molybdenum powder. Accuracy of the overall procedure was assessed via distance map comparisons between original anatomical and final metal implants. Restoration of natural ankle joint mechanics was check after implantation of each of the three sets. In a special rig, a manually-driven dorsi/plantar-flexion was applied throughout the passive arc. Additionally, at three different joint positions, joint torques were imposed in the frontal and axial anatomical planes. Mean manufacturing errors were found to be smaller than 0.08 mm. Consistent motion patterns were observed over repetitions, with the mean standard deviation smaller than 1.0 degree. In each ankle specimen, mobility, and stability at the replaced joints compared well with the original natural condition. For the first time, custom-made implants for total ankle replacements were designed, manufactured with additive technology and tested. This procedure is a first fundamental step toward the development of completely personalized prostheses. © 2018 Orthopaedic Research Society. Published by Wiley Periodicals, Inc. J Orthop Res.

Experimental evaluation of current and novel approximations of articular surfaces of the ankle joint

Kinematics and flexibility properties of both natural and replaced ankle joints are affected by the geometry of the articulating surfaces. Recent studies proposed an original saddle-shaped, skewed, truncated cone with laterally oriented apex, as tibiotalar contact surfaces for ankle prosthesis. The goal of this study was to compare in vitro this novel design with traditional cylindrical or medially centered conic geometries in terms of their ability to replicate the natural ankle joint mechanics. Ten lower limb cadaver specimens underwent a validated process of custom design for the replacement of the natural ankle joint. The process included medical imaging, 3D modeling and printing of implantable sets of artificial articular surfaces based on these three geometries. Kinematics and flexibility of the overall ankle complex, along with the separate ankle and subtalar joints, were measured under cyclic loading. In the neutral and in maximum plantarflexion positions, the range of motion under torques in the three anatomical planes of the three custom artificial surfaces was not significantly different from that of the natural surfaces. In maximum dorsiflexion the difference was significant for all three artificial surfaces at the ankle complex, and only for the cylindrical and medially centered conic geometries at the tibiotalar joint. Natural joint flexibility was restored by the artificial surfaces nearly in all positions. The present study provides experimental support for designing articular surfaces matching the specific morphology of the ankle to be replace, and lays the foundations of the overall process for designing and manufacturing patient-specific total ankle replacements.

Analysis of surface-to-surface distance mapping during three-dimensional motion at the ankle and subtalar joints

Joint surface interaction and ligament constraints determine the kinematic characteristics of the ankle and subtalar joints. Joint surface interaction is characterized by joint contact mechanics and by relative joint surface position potentially characterized by distance mapping. While ankle contact mechanics was investigated, limited information is available on joint distance mapping and its changes during motion. The purpose of this study was to use image-based distance mapping to quantify this interaction at the ankle and subtalar joints during tri-planar rotations of the ankle complex. Five cadaveric legs were scanned using Computed Tomography and the images were processed to produce 3D bone models of the tibia, fibula, talus and calcaneus. Each leg was tested on a special linkage through which the ankle complex was loaded in dorsiflexion/plantarflexion, inversion/eversion, and internal/external rotation and the resulting bone movements were recorded. Fiduciary bone markers data and 3D bone models were combined to generate color-coded distance maps for the ankle and subtalar joints. The results were processed focusing on the changes in surface-to-surface distance maps between the extremes of the range of motion and neutral. The results provided detailed insight into the three-dimensional highly coupled nature of these joints showing significant and unique changes in distance mapping from neutral to extremes of the range of motion. The non-invasive nature of the image-based distance mapping technique could result, after proper modifications, in an effective diagnostic and clinical evaluation technique for application such as ligament injuries and quantifying the effect of arthrodesis or total ankle replacement surgery.

Fluoroscopic and Gait Analyses for the Functional Performance of a Custom-Made Total Talonavicular Replacement

The present study evaluated the restoration of joint function in a special clinical case: a professional rock climber who underwent an original total talonavicular replacement with a custom-made prosthesis after a complex articular fracture. Full body gait analysis and 3-dimensional joint kinematics using single-plane fluoroscopy were performed on the same day at the 30-month follow-up examination. Gait analysis was performed using stereophotogrammetric, dynamometric, electromyographic, and baropodometric systems. Gait analysis showed good restoration of rotation, as well as moment patterns in the main lower limb and foot joints in the operated leg. At the artificial tibiotalar joint, videofluoroscopic analysis revealed a flexion capability of about 20°, together with a few degrees of motion in the frontal and transverse planes. The neighboring joints of the foot did not present with severe kinematic abnormalities. A full talonavicular replacement can be a viable and effective solution for complex ankle injury sequelae, even in patients with highly demanding functionality.