Effect of bone diameter and eccentric loading on fatigue life of cortical screws used with interlocking nails

Three-dimensionally printed osteotomy and reaming guides for correction of a multiplanar femoral deformity stabilized with an interlocking nail in a dog

OBJECTIVE

To describe the use of virtual surgical planning (VSP) and three-dimensionally (3D) printed surgical guides for corrective osteotomies stabilized with an interlocking nail in a dog with a multiplanar femoral deformity.

STUDY DESIGN

Case report.

ANIMALS

An 8-year-old male neutered mixed breed dog weighing 44 kg.

METHODS

A dog was presented for a right grade 3 lateral patellar luxation secondary to a multiplanar femoral deformity due to a suspected femoral malunion. A computed tomography (CT) scan was obtained to create virtual femoral models. Corrective osteotomies were simulated with VSP. Custom osteotomy guides and reaming guides were designed to facilitate the correction and the placement of an interlocking nail. The preoperative femoral model, virtually aligned femoral model, custom osteotomy guides, and reaming guides were 3D printed, sterilized, and utilized intraoperatively. A CT scan was performed postoperatively to assess femoral length and alignment.

RESULTS

Custom osteotomy and reaming guides were used as intended by the VSP. Postoperative femoral length as well as frontal, sagittal, and axial plane alignment were within 0.7 mm, 2.2°, 0.5°, and 1.6°, respectively, of the virtually planned femoral model. Two months postoperatively, the dog was sound on visual gait examination, and the patella tracked in the trochlear groove throughout stifle range of motion and was unable to be manually luxated. Radiographs obtained 2 months postoperatively revealed static femoral alignment and implants. Both osteotomies were discernable with callus bridging.

CONCLUSION

Virtual surgical planning and custom osteotomy and reaming guides facilitated complex femoral corrective osteotomies and interlocking nail placement.

Biomechanical comparison of titanium alloy additively manufactured and conventionally manufactured plate-screw constructs

AIM

To biomechanically compare the bending stiffness, strength, and cyclic fatigue of titanium additively manufactured (AM) and conventionally manufactured (CM) limited contact plates (LCP) of equivalent dimensions using plate-screw constructs.

METHODS

Twenty-four 1.5/2.0-mm plate constructs (CM: n = 12; AM: n = 12) were placed under 4-point bending conditions. Data were collected during quasi-static single cycle to failure and cyclic fatigue testing until implants plastically deformed or failed. Bending stiffness, bending structural stiffness, and bending strength were determined from load-displacement curves. Fatigue life was determined as number of cycles to failure. Median test variables for each method were compared using the Wilcoxon rank sum test within each group. Fatigue data was also analysed by the Kaplan-Meier estimator of survival function.

RESULTS

There was no evidence for a difference in bending stiffness and bending structural stiffness between AM and CM constructs. However, AM constructs exhibited greater bending strength (median 3.07 (min 3.0, max 3.4) Nm) under quasi-static 4-point bending than the CM constructs (median 2.57 (min 2.5, max 2.6) Nm, p = 0.006). Number of cycles to failure under dynamic 4-point bending was higher for the CM constructs (median 164,272 (min 73,557, max 250,000) cycles) than the AM constructs (median 18,704 (min 14,427, max 33,228) cycles; p = 0.02). Survival analysis showed that 50% of AM plates failed by 18,842 cycles, while 50% CM plates failed by 78,543 cycles.

CONCLUSION AND CLINICAL RELEVANCE

Additively manufactured titanium implants, printed to replicate a conventional titanium orthopaedic plate, were more prone to failure in a shorter fatigue period despite being stronger in single cycle to failure. Patient-specific implants made using this process may be brittle and therefore not comparable to CM orthopaedic implants. Careful selection of their use on a case/patient-specific basis is recommended.

Ex vivo postimplantation biomechanical properties of a press-fit cementless femoral stem with transfixation pin for canine total hip replacement

OBJECTIVE

To compare ex vivo postimplantation biomechanical characteristics of 3 implants for canine total hip replacement: a cementless press-fit femoral stem with a pin in the femoral neck (p-pfFS), a press-fit cementless femoral stem without this pin (pfFS), and a cemented femoral stem (cFS).

SAMPLE

18 cadaveric femurs from 9 dogs.

PROCEDURES

Femurs were assigned randomly to 3 groups, and biomechanical testing was performed by measuring vertical displacement during cyclic loading and resistance to failure with compression parallel to the longitudinal axis of the femur. Force-displacement curves were assessed for failure tests, and work necessary for failure was calculated.

RESULTS

No significant differences were observed in vertical displacement during cyclic loading (P = .263) or work necessary for failure (P = .079). Loads to failure for cFS and p-pfFS implants were significantly greater than that for the pfFS, but no significant difference in load to failure was observed between cFS and p-pfFS implants (P = .48).

CLINICAL RELEVANCE

Cementless femoral stems with a transfixation pin offer significantly greater immediate resistance to failure to compressive loads parallel to the longitudinal axis of the femur than standard cementless stems, and a level of stability comparable to that of cemented stems. p-pfFS implants may be valuable in total hip replacement, potentially reducing the risk of fracture during the early postoperative period prior to osteointegration.

Evaluation of a Feline Bone Surrogate and In Vitro Mechanical Comparison of Small Interlocking Nail Systems in Mediolateral Bending

OBJECTIVE

 The aim of this study was to (1) evaluate bending structural properties of a machined short fibre epoxy (SFE) feline bone surrogate (FBS), (2) compare the bending behaviour of small angle-stable interlocking nails (I-Loc; Targon) and locking compression plates (LCP) and (3) evaluate the effect of implant removal on FBS bending strength.

METHODS

 Part 1: Feline cadaveric femurs (n = 10) and FBS (n = 4) underwent cyclic four-point bending and load to failure. Part 2: Fracture gap FBS constructs (n = 4/group) were stabilized in a bridging fashion with either I-Loc 3 and 4, Targon 2.5 and 3.0, LCP 2.0 and 2.4, then cyclically bent. Part 3: Intact FBS with pilot holes, simulating explantation, (n = 4/group) underwent destructive bending tests. Bending compliance, angular deformation and failure moment (F_M) were statistically compared (p < 0.05).

RESULTS

 Native bone and FBS were similar for all outcome measures (p > 0.05). The smallest and largest bending compliance and angular deformation were seen in the I-Loc 4 and LCP 2.0 respectively (p < 0.05). While explanted Targon FBS had the lowest F_M (p < 0.05), I-Loc and LCP constructs F_M were not different (p > 0.05).

CONCLUSION

 The similar bending properties of short fibre epoxy made FBS and native feline femurs suggest that this model could be used for mechanical testing of implants designed for feline long bone osteosynthesis. The I-Loc constructs smaller angular deformation which also suggests that these implants represent a valid alternative to size-matched Targon and LCP for feline fracture osteosynthesis. The significantly lower F_M of explanted Targon may increase the risk of secondary fracture following implant removal.

Biomechanical comparison of a 3.5-mm conical coupling plating system and a 3.5-mm locking compression plate applied as plate-rod constructs to an experimentally created fracture gap in femurs of canine cadavers

OBJECTIVE To compare stiffness and resistance to cyclic fatigue of two 3.5-mm locking system plate-rod constructs applied to an experimentally created fracture gap in femurs of canine cadavers. SAMPLE 20 femurs from cadavers of 10 mixed-breed adult dogs. PROCEDURES 1 femur from each cadaver was stabilized with a conical coupling plating system-rod construct, and the contralateral femur was stabilized with a locking compression plate (LCP)-rod construct. An intramedullary Steinmann pin was inserted in each femur. A 40-mm gap then was created; the gap was centered beneath the central portion of each plate. Cyclic axial loading with increasing loads was performed. Specimens that did not fail during cyclic loading were subjected to an acute load to failure. RESULTS During cyclic loading, significantly more LCP constructs failed (6/10), compared with the number of conical coupling plating system constructs that failed (1/10). Mode of failure of the constructs included fracture of the medial or caudal aspect of the cortex of the proximal segment with bending of the plate and pin, bending of the plate and pin without fracture, and screw pullout. Mean stiffness, yield load, and load to failure were not significantly different between the 2 methods of stabilization. CONCLUSIONS AND CLINICAL RELEVANCE Both constructs had similar biomechanical properties, but the conical coupling plating system was less likely to fail than was the LCP system when subjected to cyclic loading. These results should be interpreted with caution because testing was limited to a single loading mode.

The Effects of Interlocking a Universal Hip Cementless Stem on Implant Subsidence and Mechanical Properties of Cadaveric Canine Femora

OBJECTIVE

To determine if an interlocking bolt would limit subsidence of the biological fixation universal hip (BFX(®)) femoral stem under cyclic loading and enhance construct stiffness, yield, and failure properties.

STUDY DESIGN

Ex vivo biomechanical study.

ANIMALS

Cadaveric canine femora (10 pairs).

METHODS

Paired femora implanted with a traditional stem or an interlocking stem (constructs) were cyclically loaded at walk, trot, and gallop loads while implant and bone motions were captured using kinematic markers and high-speed video. Constructs were then loaded to failure to evaluate failure mechanical properties.

RESULTS

Implant subsidence was greater (P = .037) for the traditional implant (4.19 mm) than the interlocking implant (0.78 mm) only after gallop cyclic loading, and cumulatively after walk, trot, and gallop cyclic loads (5.20 mm vs. 1.28 mm, P = .038). Yield and failure loads were greater (P = .029 and .002, respectively) for the interlocking stem construct (1155 N and 2337 N) than the traditional stem construct (816 N and 1405 N). Version angle change after cyclic loading was greater (P = .020) for the traditional implant (3.89 degrees) than for the interlocking implant (0.16 degrees), whereas stem varus displacement at failure was greater (P = .008) for the interlocking implant (1.5 degrees) than the traditional implant (0.17 degrees).

CONCLUSION

Addition of a stabilizing bolt enhanced construct stability and limited subsidence of a BFX(®) femoral stem. Use of the interlocking implant may decrease postoperative subsidence. However, in vivo effects of the interlocking bolt on osseointegration, bone remodeling, and stress shielding are unknown.

The best location for proximal locking screw for femur interlocking nailing: A biomechanical study

BACKGROUND

Proximal locking screw deformation and screw fracture is a frequently seen problem for femur interlocking nailing that affects fracture healing. We realized that there is lack of literature for the right level for the proximal locking screw. We investigated the difference of locking screw bending resistance between the application of screws on different proximal femoral levels.

MATERIALS AND METHODS

We used a total of 80 proximal locking screws for eight groups, 10 screws for each group. Three-point bending tests were performed on four types of screws in two different trochanteric levels (the lesser trochanter and 20 mm proximal). We determined the yield points at three-point bending tests that a permanent deformation started in the locking screws using an axial compression testing machine.

RESULTS

The mean yield point value of 5 mm threaded locking screws applied 20 mm proximal of lesser trochanter was 1022 ± 49 (range 986-1057) (mean ± standard deviation, 95% confidence interval). On the other hand, the mean yield point value of the same type of locking screws applied on the lesser trochanteric level was 2089 ± 249 (range 1911-2268). Which means 103% increase of screw resistance between two levels (P = 0.000). In all screw groups, on the lesser trochanter line we determined 98-174% higher than the yield point values of the same type of locking screws in comparison with 20 mm proximal to the lesser trochanter (P = 0.000).

CONCLUSION

According to our findings, there is twice as much difference in locking screw bending resistance between these two application levels. To avoid proximal locking screw deformation, locking screws should be placed in the level of the lesser trochanter in nailing of 1/3 middle and distal femur fractures.

A comparison of conventional compression plates and locking compression plates using cantilever bending in an ilial fracture model

OBJECTIVES

The purpose of this study was to compare the stiffness, yield load, ultimate load at failure, displacement at failure, and mode of failure in cantilever bending of locking compression plates (LCP) and dynamic compression plates (DCP) in an acute failure ilial fracture model. Our hypothesis was that the LCP would be superior to the DCP for all of these biomechanical properties.

METHODS

Ten pelves were harvested from healthy dogs euthanatized for reasons unrelated to this study and divided into two groups. A transverse osteotomy was performed and stabilized with either a 6-hole DCP applied in compression or a 6-hole LCP. Pelves were tested in cantilever bending at 20 mm/min to failure and construct stiffness, yield load, ultimate load at failure, displacement at failure, and mode of failure were compared.

RESULTS

The mean stiffness of DCP constructs (193 N/mm [95% CI 121 - 264]) and of LCP constructs (224 N/mm [95% CI 152 - 295]) was not significantly different. Mean yield load of DCP constructs (900 N [95% CI 649 -1151]) and of LCP constructs (984 N [95% CI 733 -1235]) was not significantly different. No significant differences were found between the DCP and LCP constructs with respect to mode of failure, displacement at failure, or ultimate load at failure.

CLINICAL SIGNIFICANCE

Our study did not demonstrate any differences between DCP and LCP construct performance in acute failure testing in vitro.

Effect of plate working length on plate stiffness and cyclic fatigue life in a cadaveric femoral fracture gap model stabilized with a 12-hole 2.4 mm locking compression plate

Background

There are several factors that can affect the fatigue life of a bone plate, including the mechanical properties of the plate and the complexity of the fracture. The position of the screws can influence construct stiffness, plate strain and cyclic fatigue of the implants. Studies have not investigated these variables in implants utilized for long bone fracture fixation in dogs and cats. The purpose of the present study was to evaluate the effect of plate working length on construct stiffness, gap motion and resistance to cyclic fatigue of dog femora with a simulated fracture gap stabilized using a 12-hole 2.4 mm locking compression plates (LCP). Femora were plated with 12-hole 2.4 mm LCP using 2 screws per fracture segment (long working length group) or with 12-hole 2.4 mm LCP using 5 screws per fracture segment (a short working length group).

Results

Construct stiffness did not differ significantly between stabilization techniques. Implant failure did not occur in any of the plated femora during cycling. Mean ± SD yield load at failure in the short plate working length group was significantly higher than in the long plate working length group.

Conclusion

In a femoral fracture gap model stabilized with a 2.4 mm LCP applied in contact with the bone, plate working length had no effect on stiffness, gap motion and resistance to fatigue. The short plate working length constructs failed at higher loads; however, yield loads for both the short and long plate working length constructs were within physiologic range.

In Vitro Mechanical Comparison of Screwed, Bolted, and Novel Interlocking Nail Systems to Buttress Plate Fixation in Torsion and Mediolateral Bending

OBJECTIVE

To compare standard interlocking nails (ILN) with a newly designed ILN featuring an angle-stable locking mechanism (ILNn).

STUDY DESIGN

Six experimental groups.

SAMPLE POPULATION

Bone models (n=48) treated with 6 and 8 mm nails locked with screws or bolts (ILN6s, ILN8s, ILN6b, ILN8b, respectively), ILNn, and a 3.5 mm broad-DCP (br-DCP); n=4/testing mode.

METHODS

Specimens were tested in torsion or 4-point bending. Construct compliance, deformation, and slack were statistically compared (P<.05).

RESULTS

Regardless of testing mode, construct compliance was greater with smaller ILN. Screwed constructs were more compliant than bolted ones, with a significant difference between ILN6s and ILN6b in torsion. Plated constructs were significantly more compliant than the ILNn. Angular deformation was consistently greater with smaller ILN. Screwed ILN constructs sustained approximately 2 x the torsional deformation of the bolted ones (approximately 36 degrees [ILN6s] versus approximately 18 degrees [ILN6b]). Comparatively, ILNn constructs had significantly less torsional (approximately 8 degrees) and bending (approximately 4 degrees) deformation than other constructs. Whereas standard ILN constructs had slack in both modes, ILNn and br-DCP construct deformations consistently occurred without slack.

CONCLUSIONS

Use of bolts rather than screws improved ILN mechanical behavior, but neither locking mechanism completely counteracted torsion and bending forces. Conversely, the ILNn angle-stable locking system eliminated torsional and bending slack, resulting in comparable mechanical performances between ILNn and plated constructs.

CLINICAL RELEVANCE

The angle-stable locking mechanism of the new ILN eliminates all slack in the system; thus, interfragmentary motion will likely be reduced compared with standard ILN, which may improve the local environment for fracture healing.

In vitro biomechanical comparison of a plate-rod combination-construct and an interlocking nail-construct for experimentally induced gap fractures in canine tibiae

OBJECTIVE

To compare structural properties of a plate-rod combination-bone construct (PRCbc) and interlocking nail-bone construct (ILNbc) by use of an experimentally induced gap fracture in canine tibiae.

SAMPLE POPULATION

12 paired canine tibiae.

PROCEDURE

Specimens were implanted with a plate-rod combination consisting of a 3.5-mm, limited-contact, dynamic-compression plate combined with an intramedullary rod or 6-mm interlocking nail. Ostectomy (removal of 10-mm segment) was performed. Paired constructs were loaded for bending, compression, or torsion measurements (4 constructs/group). Compliance was determined by fitting regression lines to the load-position curves at low (initial compliance) and high (terminal compliance) loads.

RESULTS

Bending compliances did not differ significantly between constructs. For the ILNbc, initial compliance was greater than terminal compliance in compression and torsion. Initial compliance and terminal compliance for the PRCbc were similar in compression and torsion. Initial compliance in compression and torsion was greater for the ILNbc, compared with initial compliance for the PRCbc. Maximum deformations in bending and compression were similar between constructs; however, maximum torsional angle was significantly greater for the ILNbc, compared with values for the PRCbc.

CONCLUSIONS AND CLINICAL RELEVANCE

The study documented that for an experimentally induced gap fracture in canine tibiae, a plate-rod combination is a significantly less compliant fixation method in torsion and compression, compared with an interlocking nail. Considering the deleterious effects of torsional deformation on bone healing, a plate-rod combination may represent a biomechanically superior fixation method, compared with an interlocking nail, for the treatment of dogs with comminuted tibial diaphyseal fractures.

In vitro mechanical evaluation of torsional loading in simulated canine tibiae for a novel hourglass-shaped interlocking nail with a self-tapping tapered locking design

OBJECTIVE

To describe a novel interlocking nail (ILN) and locking system and compare the torsional properties of constructs implanted with the novel ILN or a standard 8-mm ILN (ILN8) by use of a gap-fracture model.

SAMPLE POPULATION

8 synthetic specimens modeled from canine tibiae.

PROCEDURES

An hourglass-shaped ILN featuring a tapered locking mechanism was designed. A synthetic bone model was custom-made to represent canine tibiae with a 50-mm comminuted diaphyseal fracture. Specimens were repaired by use of a novel ILN or an ILN8 with screws. Specimens were loaded for torsional measurements. Construct compliance and angular deformation were compared.

RESULTS

Compliance of the ILN8 was significantly smaller than that of the novel ILN. Mean +/- SD maximum angular deformation of the ILN8 construct (23.12 +/- 0.65 degrees) was significantly greater, compared with that of the novel ILN construct (9.45 +/- 0.22 degrees). Mean construct slack for the ILN8 group was 15.15 +/- 0.63 degrees, whereas no slack was detected for the novel ILN construct. Mean angular deformation for the ILN8 construct once slack was overcome was significantly less, compared with that of the novel ILN construct.

CONCLUSIONS AND CLINICAL RELEVANCE

Analysis of results of this study suggests that engineering of the locking mechanism enabled the novel hourglass-shaped ILN system to eliminate torsional instability associated with the use of current ILNs. Considering the potential deleterious effect of torsional deformation on bone healing, the novel ILN may represent a biomechanically more effective fixation method, compared with current ILNs, for the treatment of comminuted diaphyseal fractures.