Polyurethane unicondylar knee prostheses: simulator wear tests and lubrication studies

The Clinical Use of Osteobiologic and Metallic Biomaterials in Orthopedic Surgery: The Present and the Future

As the area and range of surgical treatments in the orthopedic field have expanded, the development of biomaterials used for these treatments has also advanced. Biomaterials have osteobiologic properties, including osteogenicity, osteoconduction, and osteoinduction. Natural polymers, synthetic polymers, ceramics, and allograft-based substitutes can all be classified as biomaterials. Metallic implants are first-generation biomaterials that continue to be used and are constantly evolving. Metallic implants can be made from pure metals, such as cobalt, nickel, iron, or titanium, or from alloys, such as stainless steel, cobalt-based alloys, or titanium-based alloys. This review describes the fundamental characteristics of metals and biomaterials used in the orthopedic field and new developments in nanotechnology and 3D-printing technology. This overview discusses the biomaterials that clinicians commonly use. A complementary relationship between doctors and biomaterial scientists is likely to be necessary in the future.

Dynamic pressure analysis of novel interpositional knee spacer implants in 3D-printed human knee models

Alternative treatment methods for knee osteoarthritis (OA) are in demand, to delay the young (< 50 Years) patient's need for osteotomy or knee replacement. Novel interpositional knee spacers shape based on statistical shape model (SSM) approach and made of polyurethane (PU) were developed to present a minimally invasive method to treat medial OA in the knee. The implant should be supposed to reduce peak strains and pain, restore the stability of the knee, correct the malalignment of a varus knee and improve joint function and gait. Firstly, the spacers were tested in artificial knee models. It is assumed that by application of a spacer, a significant reduction in stress values and a significant increase in the contact area in the medial compartment of the knee will be registered. Biomechanical analysis of the effect of novel interpositional knee spacer implants on pressure distribution in 3D-printed knee model replicas: the primary purpose was the medial joint contact stress-related biomechanics. A secondary purpose was a better understanding of medial/lateral redistribution of joint loading. Six 3D printed knee models were reproduced from cadaveric leg computed tomography. Each of four spacer implants was tested in each knee geometry under realistic arthrokinematic dynamic loading conditions, to examine the pressure distribution in the knee joint. All spacers showed reduced mean stress values by 84-88% and peak stress values by 524-704% in the medial knee joint compartment compared to the non-spacer test condition. The contact area was enlarged by 462-627% as a result of the inserted spacers. Concerning the appreciable contact stress reduction and enlargement of the contact area in the medial knee joint compartment, the premises are in place for testing the implants directly on human knee cadavers to gain further insights into a possible tool for treating medial knee osteoarthritis.

A 3D-transient elastohydrodynamic lubrication hip implant model to compare ultra high molecular weight polyethylene with more compliant polycarbonate polyurethane acetabular cups

Wear remains a significant challenge in the design of orthopedic implants such as total hip replacements. Early elastohydrodynamic lubrication modeling has predicted thicker lubrication films in hip replacement designs with compliant polycarbonate polyurethane (PCU) bearing materials compared to stiffer materials like ultra-high molecular weight polyethylene (UHMWPE). The predicted thicker lubrication films suggest improved friction and wear performance. However, when compared to the model predictions, experimental wear studies showed mixed results. The mismatch between the model and experimental results may lie in the simplifying assumptions of the early models such as: steady state conditions, one dimensional rotation and loading, and high viscosities. This study applies a 3D-transient elastohydrodynamic model based on an ISO standard gait cycle to better understand the interaction between material stiffness and film thickness in total hip arthroplasty material couples. Similar to previous, simplified models, we show that the average and central film thickness of PCU (∼0.4μm) is higher than that of UHMWPE (∼0.2μm). However, in the 3D-transient model, the film thickness distribution was largely asymmetric and the minimum film thickness occurred outside of the central axis. Although the overall film thickness of PCU was higher than UHMWPE, the minimum film thickness of PCU was lower than UHMPWE for the majority of the gait cycle. The minimum film thickness of PCU also had a larger range throughout the gait cycle. Both materials were found to be operating between boundary and mixed lubrication regimes. This 3D-transient model reveals a more nuanced interaction between bearing material stiffness and film thickness that supports the mixed results found in experimental wear studies of PCU hip implant designs.

The effect of albumin and γ-globulin on synovial fluid lubrication: Implication for knee joint replacements

Total knee arthroplasty has become a routine procedure for patients suffering from joint diseases. Although the number of operations continuously increases, a limited service-life of implants represents a persisting challenge for scientists. Understanding of lubrication may help to suitably explain tribological processes on the way to replacements that become durable well into the third decade of service. The aim of the present study is to assess the formation of protein lubricating film in the knee implant. A developed knee simulator was used to observe the contact of real femoral and transparent polymer tibial component using fluorescent microscopy. The contact was lubricated by various protein solutions with attention to the behaviour of albumin and γ-globulin. In order to suitably mimic a human synovial fluid, hyaluronic acid and phospholipids were subsequently added to the solutions. Further, the change in shape and the migration of the contact zone were studied. The results showed considerable appearance differences of the contact over the swing phase of the simplified gait cycle. Regarding film formation, a strong interaction of the various molecules of synovial fluid was observed. It was found that the thickness of the lubricating layer stabilizes within around 50 s. Throughout the contact zone, protein agglomerations were present and could be clearly visualised using the applied optical technique.

Fabrication of curcumin-loaded electrospun nanofiberous polyurethanes with anti-bacterial activity

Abstract

Two series of polyurethane (PU), based on polycaprolactone (PCL) as soft segments with two different molecular weights (2000 and 530 Da), and hexamethylene diisocyanate (HDI) and 1,4-butandiol (BDO) as hard segments were synthesized to fabricate curcumin-loaded electrospun nanofibrous PCL-based PU substrate. Chemical structures of the synthesized PUs were characterized by FTIR and NMR spectroscopy techniques. The thermal properties were analyzed by differential scanning calorimetry (DSC) and surface hydrophilicity was studied by static contact angle and bulk hydrophilicity was evaluated by water uptake test. Thereafter, bead-free PU nanofiberous substrate containing curcumin was fabricated by electrospinning and morphology of the mats was observed by scanning electron microscopy (SEM). Mechanical properties of the electrospun mats in comparison with polymeric films were assessed by a universal test machine. The in vitro release of curcumin was studied by UV–Vis spectroscopy. The optical density of the bacterial solutions was used to evaluate the antibacterial activity of the curcumin-loaded nanofibrous mats against Escherichia coli (E-coli ATCC: 25922). The results showed that curcumin-loaded PU synthesized by PCL with molecular weight of 2000 Da displayed better mechanical properties as well as better antibacterial properties in wound dressing application.

Graphical abstract

Quantification of in vitro wear of a synthetic meniscus implant using gravimetric and micro-CT measurements

A synthetic meniscus implant was recently developed for the treatment of patients with mild to moderate osteoarthritis with knee pain associated with medial joint overload. The implant is distinctively different from most orthopedic implants in its pliable construction, and non-anchored design, which enables implantation through a mini-arthrotomy without disruption to the bone, cartilage, and ligaments. Due to these features, it is important to show that the material and design can withstand knee joint conditions. This study evaluated the long-term performance of this device by simulating loading for a total of 5 million gait cycles (Mc), corresponding to approximately five years of service in-vivo. All five implants remained in good condition and did not dislodge from the joint space during the simulation. Mild abrasion was detected by electron microscopy, but µ-CT scans of the implants confirmed that the damage was confined to the superficial surfaces. The average gravimetric wear rate was 14.5 mg/Mc, whereas volumetric changes in reconstructed µ-CT scans point to an average wear rate of 15.76 mm(3)/Mc (18.8 mg/Mc). Particles isolated from the lubricant had average diameter of 15 µm. The wear performance of this polycarbonate-urethane meniscus implant concept under ISO-14243 loading conditions is encouraging.

The use of compliant layer prosthetic components in orthopedic joint repair and replacement: a review

The surgical repair or treatment of degenerative joint disease has traditionally involved the substitution of synthetic materials for one or both surfaces of the joint. Engineering thermoplastics, metals, and ceramics have either been widely accepted or experimentally evaluated for use as bearing surfaces in these prostheses. When engineering thermoplastics are used, the opposing surface is a metal or a ceramic, but metal-on-metal, metal-on-ceramic, and ceramic-on-ceramic have also been used or tested. Researchers have sought the opportunity to utilize materials with compressive mechanical properties more closely matching those of the natural articular cartilage. This review discusses the theory, testing, and application of elastomers for one bearing component of articular joint prostheses.

Long-term evaluation of a compliant cushion form acetabular bearing for hip joint replacement: a 20 million cycles wear simulation

Soft bearing materials that aim to reproduce the tribological function of the natural joint are gaining popularity as an alternative concept to conventional hard bearing materials in the hip and knee. However, it has not been proven so far that an elastic cushion bearing can be sufficiently durable as a long term (∼20 years) articulating joint prosthesis. The use of new bearing materials should be supported by accurate descriptions of the implant following usage and of the number, volume, and type of wear particles generated. We report on a long-term 20 million cycle (Mc) wear study of a commercial hip replacement system composed of a compliant polycarbonate-urethane (PCU) acetabular liner coupled to a cobalt-chromium alloy femoral head. The PCU liner showed excellent wear characteristics in terms of its low and steady volumetric wear rate (5.8-7.7 mm(3)/Mc) and low particle generation rate (2-3 × 10(6) particles/Mc). The latter is 5-6 orders of magnitude lower than that of highly cross-linked polyethylene and 6-8 orders of magnitude lower than that of metal-on-metal bearings. Microscopic analysis of the implants after the simulation demonstrated a low damage level to the implants' articulating surfaces. Thus, the compliant PCU bearing may provide a substantial advantage over traditional bearing materials.

Evaluation of the wear performance of a polycarbonate-urethane acetabular component in a hip joint simulator and comparison with UHMWPE and cross-linked UHMWPE

Acetabular hip joint components manufactured from gamma-sterilized ultra high molecular weight polyethylene (UHMWPE), gamma cross-linked UHMWPE, or polycarbonate-urethane (PCU) polymers were evaluated in a hip joint simulator, using cobalt alloy femoral components, for at least 5 million cycles. The volume of material losses due to wear was calculated for each type of sample, based upon mass loss measurements, every 500,000 cycles. The loss of material for the conventional UHMWPE was much higher than for the cross-linked UHMWPE, showing about a 70% reduction in wear due to cross-linking. The material loss for the PCU samples appears to have been at least 24% lower than for the cross-linked UHMWPE. Based upon these results, the PCU material seems to have potential for use as an alternative bearing material to UHMWPE for total hip replacement surgeries.

Chondroprotective effects of a polycarbonate-urethane meniscal implant: histopathological results in a sheep model

PURPOSE

injury or loss of the meniscus generally leads to degenerative osteoarthritic changes in the knee joint. However, few surgical options exist for meniscal replacement. The goal of this study was to examine the ability of a non-degradable, anatomically shaped artificial meniscal implant, composed of Kevlar-reinforced polycarbonate-urethane (PCU), to prevent progressive cartilage degeneration following complete meniscectomy.

METHODS

the artificial meniscus was implanted in the knees of mature female sheep following total medial meniscectomy, and the animals were killed at 3- and 6-months post-surgery. Macroscopic analysis and semi-quantitative histological analysis were performed on the cartilage of the operated knee and unoperated contralateral control joint.

RESULTS

the PCU implants remained well secured throughout the experimental period and showed no signs of wear or changes in structural or material properties. Histological analysis showed relatively mild cartilage degeneration that was dominated by loss of proteoglycan content and cartilage structure. However, the total osteoarthritis score did not significantly differ between the control and operated knees, and there were no differences in the severity of degenerative changes between 3 and 6 months post-surgery.

CONCLUSION

current findings provide preliminary evidence for the ability of an artificial PCU meniscal implant to delay or prevent osteoarthritic changes in knee joint following complete medial meniscectomy.

Wear analysis of unicondylar mobile bearing and fixed bearing knee systems: a knee simulator study

Unicondylar knee arthroplasty is an attractive alternative to total knee arthroplasty for selected patients with osteoarthritis. Mobile bearing knee designs have been developed to improve knee kinematics, lower contact stresses and reduced wear of ultra-high molecular weight polyethylene compared with fixed bearing designs. This study compared in vitro wear behavior of fixed and mobile unicondylar bearing designs. Analysis was performed using a force-controlled AMTI knee simulator according to ISO 14243-1:2002(E). The wear volume of the implants was determined gravimetrically. Optical surface characterization and an estimation of wear particle size and morphology were performed. Implant kinematic data for both designs were determined. The wear rates averaged 10.7 ± 0.59 mg per 10(6) cycles for the medial and 5.38 ± 0.63 mg per 10(6) cycles for the lateral components of the mobile bearings, compared with 7.51 ± 0.29 mg per 10(6) cycles and 3.04 ± 0.35 mg per 10(6) cycles for the fixed bearings. The mobile bearings therefore exhibited higher wear rates (P<0.01) compared with the fixed bearings. The tibial polyethylene inserts of the mobile bearings showed pronounced backside wear at the inferior surface. The kinematics of both designs was similar. However, anterior-posterior translation was lower in the mobile bearings. The wear particles were mainly elongated and small in size for both designs (P=0.462). This study shows that wear may play an important role in unicondylar mobile bearing knee designs. Advantages of unicondylar mobile designs compared with fixed bearing designs, which have been proposed in terms of wear behavior and improved kinematics, could not be confirmed.

Accelerated aging, natural aging, and small punch testing of gamma-air sterilized polycarbonate urethane acetabular components

The objectives of this study were three-fold: (1) to determine the applicability of the small punch test to characterize Bionate 80A polycarbonate urethane (PCU) acetabular implants; (2) to evaluate the susceptibility of PCU acetabular implants to exhibit degradation of mechanical behavior following gamma irradiation in air and accelerated aging; and (3) to compare the oxidation of gamma-air sterilized PCU following accelerated aging and 5 years of natural shelf aging. In addition to attenuated total reflectance-Fourier transform infrared spectroscopy, we also adapted a miniature specimen mechanical test, the small punch test, for the deformable PCU cups. Accelerated aging was performed using ASTM F2003, a standard test that represents a severe oxidative challenge. The results of this study suggest that the small punch test is sufficiently sensitive and reproducible to discriminate slight differences in the large-deformation mechanical behavior of Bionate 80A following accelerated aging. The gamma-air sterilized PCU had a reduction of 9% in ultimate load after aging. Five years of shelf aging had little effect on the mechanical properties of the PCU. Overall, our findings suggest that the Bionate 80A material has greater oxidative stability than ultra-high molecular weight polyethylene following gamma irradiation in air and exposure to a severe oxidative challenge.

Pitch-based carbon-fibre-reinforced poly (ether—ether—ketone) OPTIMA® assessed as a bearing material in a mobile bearing unicondylar knee joint

The introduction of unicondylar knee prostheses has allowed the preservation of the non-diseased compartment of the knee while replacing the diseased or damaged compartment. In an attempt to reduce the likelihood of aseptic loosening, new material combinations have been investigated within the laboratory. Tribological tests (friction, lubrication, and wear) were performed on metal-on-carbon-fibre-reinforced (CFR) poly (ether—ether—ketone) (PEEK) (pitch-based) mobile unicondylar knee prostheses up to 5×106 cycles. Both a loaded soak control and an unloaded soak control (both medial and lateral components) were used to compensate for weight change due to lubricant absorption. For this material combination the loaded soak control gave slightly lower wear for both the medial and the lateral components than did the unloaded soak control. The medial components gave higher steady state wear than the lateral components (1.70 mm3 per 106 cycles compared with 1.02 mm3 per 106 cycles with the loaded soak control). The results show that the CFR PEEK unicondylar knee joints performed well in these wear tests. They gave lower volumetric wear rates than conventional metal-on-ultra-high-molecular-weight polyethylene prostheses have given in the past when tested under similar conditions. The friction tests showed that, at physiological viscosities, these joints operated in the boundary—mixed-lubrication regime. The low wear produced by these joints seems to be a function of the material combination and not of the lubrication regime.