Introduction and Aims: Due to relative motion that can occur between the polyethylene articular surface and tibial tray, backside wear of modular tibial components can be a significant contributor to wear in TKR. This study examines the backside wear performance of a tibial component system from both a laboratory and clinical perspective. Method: Polyethylene components, CR and PS, from the NexGen knee system (Zimmer Inc.) were evaluated for backside wear. These components were identified on the back surface by the manufacturer with engraved lettering of a depth ranging from 20 to 30 micrometers. Twenty-seven components retrieved after 24 to 80 months in-situ were evaluated along with six components having undergone three million cycles of laboratory knee function simulation. Backside wear was quantified by engraving mark depth and screw hole recess penetration measurements utilising a New View 5000 scanning white light interferometer (Zygo). The severity of third-body abrasion was also recorded. Results: This particular knee system utilised a peripheral rail and dovetail polyethylene locking mechanism which demonstrated little relative polyethylene to tibial tray motion during joint function simulation. Simulator testing produced backside wear of 6.4 micrometers/million cycles or 4.5 mm3/million cycles. This backside wear represented 30% of total component wear as measured gravimetrically. Backside wear in the clinically retrieved components was sufficient to completely remove the manufacturer’s engraving marks on only three of 27 components. The remaining 24 components all experienced backside wear insufficient to remove all engraving. The severity of third-body abrasion (typically bone cement) was generally associated with greater backside wear. Two of the three clinically retrieved components with worn-through lettering had evidence of significant third-body wear. In 11 clinically retrieved components (utilised on tibial trays with screw holes), backside wear was measured by comparing engraving mark depth in unworn polyethylene areas over screw recesses with engraving mark depth in areas of polyethylene contact with the tibial tray. These components demonstrated 14 micrometers of wear at an average of 37 months in-situ or 4.4 micrometers per year. None of the retrieved components were clinically associated with osteolysis. Conclusion: In this particular tibial component system, backside wear was moderate for both the joint simulator and clinically retrieved specimens. Backside wear does not appear to be the major contributor of total polyethylene wear in this implant system. The presence of third-body particles contributed to greater wear

Particles generated at the non articulating surface (backside) of modular acetabular components have been implicated in the development of periprosthetic osteolysis after total hip arthroplasty. Several design changes have been introduced in modern uncemented acetabular cups in an attempt to reduce backside wear, including the use of so called “non-modular cups”. We compared the backside wear of retrieved cementless non-modular cups, with modular cups of first and second generation designs. Nine retrieved non-modular cups (Implex) were match paired for time in situ, patient age and weight, with 9 retrieved Trilogy cups, 9 Harris-Galante 1, and 9 Harris-Galante 2. The average time in situ was 2.5 years (1 to 7). The backside was divided in quadrants and each rated utilizing a score with a value from 0 (absence of wear) to 3 (severe backside wear) for a total ranging from 0 to 12. The score was validated for intra and inter observer reproducibility. Among 36 quadrants in the HG1 group there were 3 rated 1, 23 rated 2, and 10 rated 3. In the HG2 group, there was 1 quadrant rated 0, 16 rated 1, 14 rated 2, and 5 rated 3. In the Trilogy group, there were 6 quadrants rated 0, 27 rated 1, and 3 rated 2. In the Implex group, there were 15 quadrants rated 0, 21 rated 1. The average total backside wear score and 95%CI were 8.4 (7.6–9.3); 7.3 (5.5–9.1); 3.7 (3.2–4.1); and 2.3 (1.3–3.4) respectively. The HG1 and HG2 groups demonstrated similar backside wear scores (p=0.3). The HG1 and HG2 designs demonstrated significantly more backside wear than the Trilogy and Implex (p< 0.01). The differences between the Trilogy and the Implex were not significant in this cohort. A comparison of the “in vivo” backside wear of first generation and modern acetabular cups has not been published to date. Despite the limitations imposed by the small sample studied, the presence of multiple screw holes in the HG retrievals, and sub-optimal matching for sex, height, and varied indication for revision, we detected significant reduction in the backside wear of modern modular and non-modular acetabular cups when compared to first generation modular designs

Backside wear is generated at the non-articulating surfaces of modular acetabular cups. We compared the backside wear of retrieved liners from cementless non-modular and modular cups of first and second generation designs. We match paired for time in situ, patient age and weight, 9 retrieved Harris Galante type 1 liners, 9 Harris Galante type 2, 9 Trilogy, and 9 liners from a modern two-piece preassembled cup (Implex). The average time in situ was 2.5 years (1 to 7). The backside was divided in quadrants and each one examined under a 10x binocular loupe and rated with a score from 0 (absence of wear) to 3 (severe backside wear) for a total ranging from 0 to 12. Among 36 quadrants in the HG1 group there were 3 rated 1, 23 rated 2, and 10 rated 3. In the HG2 group, there was 1 quadrant rated 0, 16 rated 1, 14 rated 2, and 5 rated 3. In the Trilogy group, there were 6 quadrants rated 0, 27 rated 1, and 3 rated 2. In the Implex group, there were 15 quadrants rated 0, 21 rated 1. The average total backside wear score was 8.4; 7.3; 3.7; and 2.3 respectively. The HG cups demonstrated more severe backside wear than the Trilogy and Implex (HG1 vs Trilogy and HG1 vs Implex: p< 0.001; HG2 vs Trilogy and HG2 vs Implex: p< 0.02). There was a tendency towards less backside wear in the Implex cup when compared to the Trilogy (p=0.04). The difference between the HG1 and HG2 was not significant. Despite the limitations imposed by the small sample studied, the presence of multiple screw holes in the Harris-Galante retrievals, and sub-optimal matching for sex, height, and varied indication for revision, we detected significant reduction in the backside wear of modern modular and non-modular acetabular cups when compared to first generation modular designs

Wear of the underside of modular tibial inserts (“backside wear”) has been reported by several authors. However, the actual volume of material lost through wear of the backside surface has not been quantified. This study reports the results of computerized measurements of tibial inserts of one design known to have a high incidence of backside wear in situ. A series of retrieved TKA components of one design (AMK, Depuy) with evidence of severe backside wear and extrusions of the polyethylene insert were examined. The three-dimensional surface profile of the backside of each insert was digitized and reconstructed with CAD software (UniGraphics). The volume of material removed was calculated from the volume between the worn backside surface and an “initial” surface defined by unworn areas. Computer reconstructions showed that in all retrievals, the unworn surface of the remaining pegs, the rim of material extruded over the medial edge and unworn surfaces on the anterior-lateral edge all lie in a single plane. This demonstrates that the “pegs” present on the backside of these inserts correspond to residual, unworn protrusions remaining on each retrieved component and do not represent cold flow extrusions through the base plate holes. The average volume of material lost due to backside wear was 608mm^3 ± 339mm^3 (range:80–1599 mm^3). This corresponds to an average loss of 569mg and an average linear wear rate of 103mg/year, based on the time in situ for each implant. The volume of material removed due to backside wear is significant and is of a magnitude large enough to generate osteolysis. Our results indicate that the appearance of pegs on the underside of components with screw holes on the baseplate are not due to creep, but instead are due to severe wear of the insert. The mechanisms of material removed due to pitting and burnishing actually produce debris of a size more damaging in terms of osteolysis than wear at the articulating surface making it clear that significant improvements in implant design are needed to prevent backside wear and osteolysis

Particles generated at the non articulating surface (backside) of modular acetabular components have been implicated in the development of periprosthetic osteolysis after THA. Several design changes have been introduced in modern acetabular cups in an attempt to reduce backside wear, including the use of “non-modular cups”. We compared the backside wear of retrieved cementless non-modular cups, with modular cups of first and second generation designs. Nine retrieved non-modular cups (Implex) were match-paired for time-in-situ, patient age and weight, with 9 retrieved Trilogy cups, 9 Harris-Galante 1, and 9 Harris-Galante 2. The average time in situ was 2.5 years (1–7). The backside was divided in quadrants and each rated with a value from 0 (absence of wear) to 3 (severe backside wear) for a total ranging from 0 to 12. This new score was validated for intra and inter observer reproducibility. Among 36 quadrants in the HG1 group there were 3 rated 1, 23 rated 2, and 10 rated 3. In the HG2 group, 1 quadrant was rated 0, 16 rated 1, 14 rated 2, and 5 rated 3. In the Trilogy group, 6 quadrants were rated 0, 27 rated 1, and 3 rated 2. In the Implex group, 15 quadrants were rated 0, 21 rated 1. The average backside wear score and 95%CI were 8.4 (7.6–9.3); 7.3 (5.5–9.1); 3.7 (3.2–4.1); and 2.3 (1.3–3.4) respectively. The HG cups demonstrated more severe backside wear than the Trilogy and Implex (p< 0.02). There was a tendency towards less backside wear in the Implex cup when compared to the Trilogy (p=0.04). The difference between the HG1 and HG2 was not significant. We detected significant reduction in the backside wear of modern modular and non-modular acetabular cups when compared to first generation modular designs

Introduction. Large-scale retrieval studies have shown backside wear in tibial inserts is dependent on the surface roughness of the tibial tray. Manufacturers acknowledge this design factor and have responded with the marketing of mirror-finished trays, which are clinically proven to have lower wear rates in comparison to historically “rough” (e.g. grit blasted) trays. While the relationship between wear and surface roughness has been explored in other polymer applications, the quantitative dependence of backside wear rate on quantitative surface finish has not yet been established for modern devices. The present study evaluates small-excursion polyethylene wear on pucks of a variety of surface roughnesses. The objective of this study is to determine where inflection points exist in the relationship between surface roughness and wear rate. Materials and Methods. An AMTI Orthopod, 6-station pin on disk tribotest was designed to mimic worst-case in vivo backside wear conditions based on published retrieval analyses. Titanium (Ti6Al4V) pucks with six different surface roughness preparations (Sa ranges from 0.06 um to 1.06 um) were characterized with white light profilometry. Never implanted polyethylene tibial inserts (never irradiated, EtO sterilized) were machined into 6 mm diameter cylindrical pins. Fretting-type motion was conducted in a 2mm square pattern at 2Hz under 100 N constant force in 25% bovine serum lubricant for 1.35 million cycles in triplicate. Mass measurements were taken every 225 thousand cycles. Results. Over the range of surface roughness studied (Sa = 0.06 – 1.06 µm), wear rate grew logistically. The wear rate for highly polished titanium (Sa = 0.06 µm) was not statistically different from less-polished titanium with Sa of 0.14 µm (p > 0.1). Titanium pucks having the highest surface roughness (Sa > 0.5µm), removed material significantly faster than those with roughness less than 0.3µm. The results of these tests suggest that Ti trays with Sa less than 0.15µm may yield equivalent clinical backside wear results, while pucks with Sa greater than 0.15µm begin to have increased wear rates that may be clinically significant. The two pucks with Sa greater than 0.5 µm yielded wear rates failing to be statistically differentiable (p = 0.059), corresponding with the flattening of the logistic curve. Discussion. These results suggest that baseplates with Sa less than 0.15 µm may ultimately yield clinically equivalent outcomes. The wear rate curve changes slope between Sa 0.14 and 0.22 µm and continues to increase across the range of surface roughnesses studied. The wear rates on rough pucks (Sa > 0.5 µm) showed high variation, reducing the ability to distinguish the two statistically (p = 0.059). Further study will better distinguish wear properties at higher surface roughnesses. Conclusion. These findings demonstrate that there may be a range of finishes between a mirror polish and grit blast that may produce clinically equivalent wear rates. This work provides justification for further study into the relationship between backside wear, baseplate tray roughness, and material choices. For any figures or tables, please contact authors directly

Introduction. Backside wear of polyethylene (PE) inlays in fixed-bearing total knee replacement (TKR) generates high number of wear debris, but is poorly studied in modern plants with improved locking mechanisms. Aim of study. Retrieval analysis of PE inlays from contemporary fixed bearing TKRs - to evaluate the relationship between backside wear and liner locking mechanism and material type and roughness of the tibial tray. Methods. MATERIAL. We included five types of implants, revised after min. 12 months (14–71): three models with a peripheral locking rim and two models with a dove-tail locking mechanism. Altogether this study included 15 inlays were removed from TKRs with CoCr alloy tray with a roughened surface and a peripheral locking lip liner (Stryker Triathlon, Ra 5,61 µm), 9 from CoCr trays with peripheral locking lip and untreated surface (Aesculap Search, Ra 0,81 µm), 13 from Ti alloy trays with peripheral locking lip and untreated surface (DePuy PFC Sigma 0,61 µm), 11 from Ti alloy trays with untreated surface and dovetail locking mechanism (Zimmer NexGen, 0,34 µm), and 9 from iplants with a Ti alloy tibial tray with mirror polished surface and dovetail locking mechanism (Smitn&Nephew Genesis II, 0,11 µm). METHODS. Wear of bearing surface and back side of retrieved inlays was examined in 10 sectors under a light microscope. Seven modes of wear were analysed and quantified according to the Hood scale: surface deformation, pitting, embedded third bodies, pitting, scratching, burnishing (polishing), abrasion and delamination. Damage of inlays caused by backside wear was also evaluated using scanning electron microscopy (SEM). Roughness of tibial tray was evaluated using a contact profilometer. Results. We found no differences between wear scores on the articulating surface in all group, they did not correlate with backside wear scores in all groups as well. Compared to all other groups, backside wear scores were significantly higher in implants with untreated Ti alloy tibial tray (P<0,001 Wilcoxon test). Lowest wear rates were found in implants from both Ti and CoCr alloys and peripheral locking rim. Interestingly there was no difference between wear of implants with polished and untreated surface (Fig. 1). SEM analysis demonstrated different wear modes in implants with dovetail mechanism and peripheral rim. The first group demonstrated signs of gross rotational instability, with severe abrasion with an arch-shaped pattern and delaminated PE (Fig 2). In one design we observed severe extrusion of PE into screw holes of the tibial tray. Inlays from trays with peripheral rim presented two types of wear: flattening of machining marks or protrusion of the material caused by the rough surface (Fig 3). Conclusions. This study demonstrates that backside wear is still a problem in modern TKR. Our findings suggest that it is predominantly affected by type of locking mechanism (with peripheral rim performing better), to a lesser extent by surface roughness of the tibial component, while material type does not seem to play an important role. This study was funded by a grant from the National Science Centre nr 2012/05/D/NZ5/01840. To view tables/figures, please contact authors directly

Introduction. Ideally, standardized wear testing protocols replicate the in vivo motions and forces of TKR patients. In a previous study with 30 TKR patients, two distinct in vivo gait patterns emerged, one characterized as having low anteroposterior (AP-L) motion and the other high anteroposterior (AP-H) motion. The aim of this study was to determine the effect of the two in vivo-determined gait patterns on total and backside insert wear in comparison with the ISO standard 14243-3. In order to differentiate and accurately quantify topside and backside wear, a novel technique was employed where different lanthanide tracers are incorporated into the polyethylene during manufacture. Materials and Methods. Components from the Zimmer NexGen CR Knee Replacement System were used. Europium (Eu) and Gadolinium (Gd)-stearates were mechanically mixed with GUR1050 UHMWPE resin to obtain two tracer-UHMWPE resins containing 49.1±1.5 ppm Eu and 68.8±1.6 ppm Gd, respectively. 12 grams of the Eu-doped resin was placed on the bottom, 10 grams of virgin GUR1050 resin was placed in the middle, and 10 grams of Gd-doped resin was placed on the top to mold NexGen CR tibial inserts. The backside was then machined to interlock with the tibial baseplate. The minimum insert thickness was 10 mm. All inserts were packaged in nitrogen and gamma sterilized. The wear test was conducted on a 4-station knee simulator in displacement-control mode. Simulator input was obtained from ISO 14243-3 and from gait of 30 NexGen TKR subjects, previously categorized into low (AP-L) and high (AP-H) anteroposterior motion groups. Per station, each insert was sequentially subjected to ISO, AP-L, AP-H motion for 2 Mc at 1 Hz. Subsequently, the ISO profile was repeated. Tibial inserts were weighed and lubricant samples were taken after every 0.5 Mc interval. Knowing the Eu and Gd concentrations from ICP-MS analysis, and normalizing those to the concentrations in the polyethylene inserts, the localized (Eu – backside; Gd – topside) wear was calculated. Wear particle analysis was conducted following established protocols. Results. For all tested liners (n=4 + soak) during the three tested motion profiles, the chemically calculated wear correlated closely with the gravimetrically determined wear (R. 2. »0.8), with slopes not different from 1. Both in vivo motion groups displayed higher wear rates than the ISO group following the order of the AP motion amplitudes (Figure). Backside wear for ISO constituted 2.76% ± 0.90% (mean ± SE) of the total wear, increasing significantly to 15.8 ± 3.2% for AP-L and further increasing to 19.3 ± 0.95% for AP-H (p<.001). The mean wear particle sizes were under 200 nm for all three motion patterns, being largest for the AP-H gait protocol (Table). Discussion. Both in vivo motion groups displayed higher wear rates than the group tested per ISO standard 14243-3. Interestingly backside wear was affected the most and increased 4.5 to 6-fold over ISO. Testing for the proportion of backside wear across various activities of daily living may therefore be an important consideration in evaluating knee prostheses wear and could be facilitated by this new tracer technology. For any figures or tables, please contact the authors directly

Previous retrieval studies demonstrate increased tibial baseplate roughness leads to higher polyethylene backside wear in total knee arthroplasty (TKA). Micromotion between the polyethylene backside and tibial baseplate is affected by the locking mechanism design and can further increase backside wear. The purpose of this study was to examine modern locking mechanisms, in the setting of both roughened and polished tibial baseplates, on backside tibial polyethylene wear. Five TKA models were selected, all with different tibial baseplate and/or locking mechanism designs. Six retrieval tibial polyethylenes from each TKA model were matched based on time in vivo (TIV), age at TKA revision, BMI, gender, number of times revised, and revision reason. Two observers scored each polyethylene backside according to a visual damage score and individual damage modes. Primary outcomes were mean damage score and individual damage modes. Demographics were compared by one-way ANOVA. Damage scores and modes were analysed by the Kruskal-Wallis test and Dunn's multiple comparisons test. There were no differences among the groups based on TIV (p=0.962), age (p=0.651), BMI (p=0.951), gender, revision number, or reason for revision. There was a significant difference across groups for mean total damage score (p=0.029). The polished tibial design with a partial peripheral capture locking mechanism and anterior constraint demonstrated a significantly lower score compared to one of the roughened tibial designs with a complete peripheral-rim locking mechanism (13.0 vs. 22.1, p=0.018). Otherwise, mean total damage scores were not significant between groups. As far as modes of wear, there were identifiable differences among the groups based on abrasions (p=0.005). The polished design with a tongue-in-groove locking mechanism demonstrated a significantly higher score compared to both groups with roughened tibial baseplates (5.83 vs. 0.83, p=0.024 and 5.83 vs. 0.92, p=0.033). Only the two designs with roughened tibial baseplates demonstrated dimpling (5.67 and 8.67) which was significant when compared against all other groups (p0.99). No other significant differences were identified when examining burnishing, cold flow, scratching, or pitting. No polyethylene components exhibited embedded debris or delamination. Total damage scores were similar between all groups except when comparing one of the polished TKA design to one of the roughened designs. The other TKA model with a roughened tibial baseplate had similar damage scores to the polished designs, likely due to its updated locking mechanism. Dimpling wear patterns were specific for roughened tibial baseplates while abrasive wear patterns were identified in the design with a tongue-in-groove locking mechanism. Our study showed even in the setting of a roughened tibial baseplate, modern locking mechanisms decrease backside wear similar to that of other current generation TKA designs

TKR backside wear studies have concluded that, compared to rough trays, polished trays decrease total amount of backside wear by 80% to 87%. However, size and volumetric concentration of sub-micron-sized polyethylene particles are critical factors for macrophage-mediated osteolysis. We assessed the size and morphology of polyethylene wear debris from TKR backside wear simulations comparing polyethylene fretting against polished and blasted metal surfaces. A 3-station fretting wear simulator reproduced loads and motions typical of the backside of fixed-bearing inserts of TKRs. 5-million cyclic experiments combined low (50μm) or high (200μm) linear motion with +3o rotational motion. Load profile was double-peak Paul curve (peak 10MPa). Eight 3-station experiments measured polyethylene wear against blasted or polished metal surfaces of Ti6Al4V or CoCr. Polyethylene particles were isolated from serum following gradient separation and filtration on 0.01μm polycarbonate filters. Using SEM analysis, average 200 particles per sample were characterized with Meta-morph™ image analysis software. Concentration of submicron particles in the debris from rough surfaces was 31–32% under 50μm motion, 28–30% under 200μm. Surprisingly, this concentration from polished surfaces was substantially greater: 69–78% (50μm), and 57–63% (200μm). However, total poly wear against rough surfaces was 0.45–1.63mm3/. Mcycles, and 0–0.35mm3/Mcycles against polished. Taking this into account, the volume of submicron particles from polished surfaces is less than 0.1mm3/ Mcycles and from rough surfaces between 0.1 and 0.45mm3/Mcycles. In conclusion, although polished metal trays produce up to five times less wear than blasted surfaces, they may also lead to an increase in the osteolytic potential of the polyethylene debris

Introduction:. Backside wear has been previously reported through in-vitro and in-vivo to have a significant contribution to the total wear in rotating bearing TKRs. The present study investigated the contribution of backside wear to the total wear in the PFC Sigma rotating platform mobile bearing TKR. In addition, the wear results were compared to the computed wear rates of the PFC Sigma fixed bearing TKR, with two different bearing materials. Materials and Methods:. The commercially available PFC Sigma rotating platform mobile bearing and PFC Sigma fixed bearing total knee replacements, size 3 (DePuy, UK) were tested, with either conventional or moderately cross-linked (5 MRad) GUR1020 UHMWPE bearing materials. The computational wear model for the knee implants was based on the contact area and an independent experimentally determined non-dimensional wear coefficient [1,2,3]. The experimental wear test for the mobile bearing was force controlled using the ISO anterior-posterior force (ISO14243-1-2009). However, due to time limitation of the explicit simulation required to run the force controlled model, the simulation was run using the AP displacements taken from the experimental knee simulator which was run under the ISO AP force. The Sigma fixed bearing TKR was run under high level of anterior-posterior displacements (maximum of 10 mm). Results and Discussion:. The rotating platform bearing showed lower wear rates, compared to that of the PFC Sigma fixed bearing, for both conventional and moderately cross-linked UHMWPE bearing materials (Fig. 1). Moreover, the results showed a high contribution of backside wear to the total wear, approximately 1 mm. 3. /million cycles (∼30% of the total wear). The computational wear predictions were in good agreements with the clinical and experimental measurements [4,5]. Contrasting the effect of bearing material on wear prediction, introducing the moderately cross-linked UHMWPE as a bearing material reduced the predicted wear rates by approximately 1 mm. 3. /million cycles in rotating platform bearing, compared to more than 5 mm. 3. /million cycles in PFC fixed bearing TKR. This reduced effect of cross-linking on wear in mobile bearing was mainly attributed to the lower cross-shear ratios in these bearings, compared to fixed bearings, and the less dependency of wear in moderately cross-linked UHMWPE on the degree of cross-shear, compared to conventional UHMWPE. Decreasing the degree of cross-shear from higher values (Sigma curved insert, high kinematic) to lower ones (rotating platform bearing) changed the predicted wear rates from 8.7 to 3.3 and from 3.4 to 2.4 (mm. 3. /million cycles), for conventional and moderately cross-linked UHMWPE materials respectively (Fig. 2). Conclusion:. The modelling confirmed the previous experimental observations of very low wear with the rotating platform knee. The models also determined the level of wear from the backside of the rotating platform knee which was approximately 1 mm. 3. /million cycles. The fixed bearing knee with moderately cross linked polyethylene also showed low wear at approximately 3 mm. 3. /million cycles. These low wear rates were determined under high kinematic walking cycles conditions. Future work will consider additional conditions

Purpose. Previous retrieval studies demonstrate increased tibial baseplate roughness leads to higher polyethylene backside wear in total knee arthroplasty (TKA). Micromotion between the polyethylene backside and baseplate is affected by the locking mechanism design and can further increase backside wear. This study's purpose was to examine modern locking mechanisms influence, in the setting of both polished and non-polished tibial baseplates, on backside tibial polyethylene damage and wear. Methods. Five TKA models were selected with different tibial baseplate and/or locking mechanism designs. Six retrieval tibial polyethylenes from each TKA model were matched based on time in vivo (TIV), age at TKA revision, BMI, gender, number of times revised, and revision reason. Two observers visually assessed each polyethylene. Primary outcomes were visual damage scores, individual visual damage modes, and linear wear rates determined on micro-computed tomography (micro-CT) scan in mm/year. Demographics were compared by one-way ANOVA. Damage scores, damage modes, and linear wear were analyzed by the Kruskal-Wallis test and Dunn's multiple comparisons test. Results. There were no differences among the groups based on TIV (p=0.962), age (p=0.609), BMI (p=0.951), gender, revision number, or reason for revision. There was a significant difference across groups for visual total damage score (p=0.031). The polished tibial design with a partial peripheral capture locking mechanism and anterior constraint demonstrated a significantly lower score compared to one of the non-polished tibial designs with a complete peripheral-rim locking mechanism (13.0 vs. 22.0, p=0.019). Otherwise, mean total damage scores were not significant between groups. There were identifiable differences among the groups based on abrasions (p=0.006). The polished design with a tongue-in-groove locking mechanism demonstrated a significantly higher score compared to one of the designs with a non-polished baseplate (5.83 vs. 0.83, p=0.016). Only the two designs with non-polished baseplates demonstrated dimpling (5.67 and 8.67), which was significant when compared against all other groups (p<0.0001), but not against each other (p>0.99). No other significant differences were identified when examining burnishing, cold flow, scratching, or pitting. No polyethylene components exhibited embedded debris or delamination. There was a significant difference among groups for linear wear on micro-CT scanning (p=0.003). Two of the polished baseplate designs, one with the partial peripheral rim capture and one with the tongue-in-groove locking mechanism, demonstrated significantly lower wear rates than the non-polished design with a complete peripheral-rim locking mechanism (p=0.008 and p=0.032, respectively). There were no other differences in wear rates between groups. Conclusions. Total damage scores and wear rates were similar between all groups except when comparing two of the polished TKA designs to one of the non-polished baseplate designs. The other TKA model with a non-polished tibial baseplate had similar damage scores and wear rates to the polished designs, likely due to its updated locking mechanism. Dimpling was specific for non-polished tibial baseplates while abrasions were identified in the design with a tongue-in-groove locking mechanism. Our study showed even in the setting of a non-polished tibial baseplate, modern locking mechanisms can decrease backside damage and wear similar to that of other current generation TKA designs. For any figures or tables, please contact authors directly (see Info & Metrics tab above).

Introduction: Full flexion is a critical performance requirement for patients with total knee replacement (TKR). Different design strategies, such as the post-and-cam, are used to achieve greater femoral rollback during knee flexion. However, substantial damage to the polyethylene tibial post on some posterior cruciate ligament substituting (PS) TKR designs has led to concerns that femoral camtibial post contact will lead to increased insert micromotion and backside wear in modular PS TKR designs. This study evaluated in vivo knee function and polyethylene wear in patients with posterior cruciate ligament retaining (CR) and PS tibial component designs with a full peripheral rim modular locking mechanism. Methods: Motion Analysis: Thirty two knees with CR (9 knees) and PS (23 knees) tibial inserts participated in fluoroscopic motion analysis during activities of daily living, including stairrise/descent, treadmill gait and maximum kneeling flexion. The metal tibial components used the same full peripheral rim locking mechanism design with the different modular polyethylene articular surfaces. Tibial-femoral contact locations were determined throughout the full range of motion for all activities. Retrieval Analysis: Polyethylene tibial inserts were retrieved during autopsy and revision surgery after 1 to 74 months. There were 37 CR inserts and 7 PS inserts of the same designs that were evaluated in the motion study. Backside damage on the inserts was assessed on all retrieved inserts using optical microscopy and the damage area and location was measured using digital image analysis. Results: A relatively posterior position of the femoral component on the tibia was significantly correlated with greater maximum knee flexion. PS TKR had significantly more posterior femoral position and greater maximum flexion than CR TKR. The mean backside damage area was 38%+10% for PS inserts and 45%+15% for CR inserts. Backside surface damage was concentrated near the inserts’ peripheral rim and was dimpled in appearance, consistent with a cast impression of the textured metal baseplate. Scratches and burnishing was infrequently observed. Inserts with the greatest area of backside damage were in-situ for the longest time period. Discussion: This fluoroscopy-based motion analysis study showed that knees with PS TKR achieve greater maximum flexion than knees with CR TKR. However, retrieved PS inserts did not have larger backside damage areas and the damage pattern location was consistent for both articular geometries. The observed damage morphology suggests that backside damage resulted from axial compression of the polyethylene insert against the textured baseplate rather than micromotion. Previous mechanical tests of this same modular tibial component design have shown that motion between the polyethylene insert and metal baseplate does not increase even after more than six years of in-vivo function

BACKGROUND: Clinical results at 10–14yrs of the NKI noncemented TKA(AAOS 2005, Plaster) showed no failure of ingrowth and no tibial osteolysis. A similar 10yr study of the NKII series indicated a higher revision rate based solely on tibial osteolysis at the tip of the medial screw, creating a 9% partial revision rate (poly-exchange and grafting of cyst) of NKII at 10yrs. There is no failure of the actual ingrowth bond.

METHODS: Between Dec 1995–01, 1410 pts were implanted with NKIIs (Zimmer). Prospective data was collected at preop, surgery & intervals up to 5–10yrs. Classification of osteolytic cysts is defined: Grade 1=cyst of 1cm; Grade 2=cyst > 1cm without cortial erosion; Grade 3A=cyst < 1cm with cortical erosion; Grade 3B=cyst 1cm with cortical erosion & Grade 4=stress fracture or perosteal reaction indicative of a stress fracture. Specimens from revisions have been evaluated by 2 independent labs. Inserts were replaced using a highly crosslinked poly.

RESULTS: 445 pts were seen for clinical and xray f/u, 65 expired. Osteolysis occurred in 36% most of which were early stages. Revision were required in 9%. Exams of the poly show wear with football shaped extrusions into the screw holes & abrasive scores consistent with micromotion. Microscopic analysis show macrophages with inclusions suggestive of poly debris but there is a paucity of actual poly seen.

DISCUSSION: Osteolytic cysts are occurring in the NKII & not in NKI. It is not known if these are design issues or poly “improvement” issues. One postulation is smaller particles but increasing numbers has led to a decrease in the bone tolerance. Early f/u of highly cross-linked poly shows marked improvement and no cysts.

Generation of the tibial cyst is multifactorial. Implantation techniques can increase poly imminence impingement by the femoral notch thus increasing forces on poly during gait. Lowering the notch on the NKII improves patella contact but can lead to impingement if the surgeon flexes the femur or places too much slope on the tibia. Hydraulic action is also postulated, joint fluid is being forced down the screw channel carrying with it small poly particles. The tight peripheral tolerances of the insert into the baseplate may create such a tight fit that the insert acts like a piston with each step. Lab testing is currently being done to test this hypothesis and evaluate micromotion and wear patterns. We are recommending polyexchanges for stg 3 & 4 pts to the highly crosslinked poly as well as curetting and grafting all cysts. Early results show cyst resolution. Stress fractures may require long stem revision baseplates. Stg 1 & 2 can be followed with serial xrays

Aims. Micromotion of the polyethylene (PE) inlay may contribute to backside PE wear in addition to articulate wear of total knee arthroplasty (TKA). Using radiostereometric analysis (RSA) with tantalum beads in the PE inlay, we evaluated PE micromotion and its relationship to PE wear. Methods. A total of 23 patients with a mean age of 83 years (77 to 91), were available from a RSA study on cemented TKA with Maxim tibial components (Zimmer Biomet). PE inlay migration, PE wear, tibial component migration, and the anatomical knee axis were evaluated on weightbearing stereoradiographs. PE inlay wear was measured as the deepest penetration of the femoral component into the PE inlay. Results. At mean six years’ follow-up, the PE wear rate was 0.08 mm/year (95% confidence interval 0.06 to 0.09 mm/year). PE inlay external rotation was below the precision limit and did not influence PE wear. Varus knee alignment did not influence PE wear (p = 0.874), but increased tibial component total translation (p = 0.041). Conclusion. The PE inlay was well fixed and there was no relationship between PE stability and PE wear. The PE wear rate was low and similar in the medial and lateral compartments. Varus knee alignment did not influence PE wear. Cite this article: Bone Joint Res 2024;13(5):226–236

In total hip arthroplasty (THA), cementless cup without screw holes has the putative benefits of maximizing host bone contact and reducing osteolysis by eliminating channels to backside wear particles. However, supplemental trans-acetabular screws cannot be used. 74 hips in 60 patients receiving same model of cementless cup without screw holes (Depuy Duraloc 100 HA cup) from 6/1999 to 3/2003 were prospectively followed up. All patients were allowed to have immediate full weight bearing. Age at THA was 53 ± 13 (range 24–74) years. Osteonecrosis was the leading hip disease (45% of hips). Survivorship was assessed using revision of the cup as the end point. Radiological parameters, including lateral opening angle, vertical and horizontal migration distances of the cups were measured. Paired t-test was used to compare between the measurements in early postoperative period and at final follow up. 51 hips were assessed at minimum 20 years follow-up. The mean follow-up was 22.6 (range 21 – 25) years. All the cups were well fixed. There were two cup revisions. Conventional polyethylene (PE) was used in both hips; osteolysis occurred 17 and 18 years later. Both cups were well fixed but were revised, one due to cup mal-positioning, one due to need in upsizing the articulation. 14 other hips were revised but these cups were well fixed and not revised; 9 loosened stems (most were cemented Elite plus stems), 5 PE wear and osteolysis (all were conventional PE). At 20 years, the survivorship of cups was 96.1%. Changes in lateral opening angle, vertical and horizontal migration distances were 0.44±1.59°, 0.01±1.52mm and -0.32±1.47mm respectively, without statistical significance. This study provided evidence of excellent long-term survivorship of cementless cup without screw holes. Immediate postoperative weight-bearing also did not lead to cup migration in the long-term

Both backside and articular surface wear have been linked to osteolysis after total knee arthroplasty (TKA). Prostheses with cementless fixation, screw holes in high load regions, and thin polyethylene are susceptible to backside wear. Factors associated with articular wear are similarly well defined. Micromotion at the modular polyethylene interface has been reported for many prostheses, but the relevance of such data compared to articular motions and wear are difficult to appreciate. This study compares in vivo motions and wear occurring at the backside and articular surfaces after TKA. Contemporary PCL-retaining prostheses from one manufacturer were implanted by one surgeon using cement fixation. The polyethylene inserts were > 6mm thick with a full peripheral rim capture and anterior wire locking mechanism. Femoral condylar motions were measured in 20 knees using fluoroscopic analysis during stair and gait activities. All patients had good to excellent clinical outcomes at one year follow-up. Articular and backside surface damage was evaluated on 32 polyethylene inserts retrieved after 27 months (1 to 71) months in-situ for infection (9), autopsy (6), patellar resurfacing (4), patellar loosening (4), tibial loosening (3), osteolysis (2), and other (4). Femoral condylar translation over the polyethylene articular surface ranged from 5-10 mm, which is substantially larger than the reported 50-500 micron range of backside interface micromotion measured in vitro. Damage covered < 33% of the backside surface and appeared as a cast impression of the opposed metal tibial component without scratches associated with micromotion. In contrast, damage consisting predominantly of scratching, burnishing and tractive striations covered 46% of the articular surface. Different locking mechanisms for modular polyethylene inserts result in different degrees of backside wear. No significant backside wear was observed these retrieved inserts with a wire-supplemented peripheral capture. Given the abrasive wear mechanisms and particulate debris shed during femoral condylar sliding, efforts to control motions at the articular surface appear warranted

Introduction. This study was performed to investigate the failure mechanism of one specific hip arthroplasty cup design that has shown a high clinical failure rate. The aim of this study was to identify general design problems of this polyethylene inlay. Material and Methods. 55 consecutive retrievals of a cementless screw ring (Mecron) were collected. In any case a 32 mm ceramic head was used. All implants failed due to aseptic loosening. The follow-up of the implants was 3 to 16 years. We recorded backside wear, fatigue of the polyethylene at the flanges on the outer rim and at the cup opening (32 mm inner diameter). To assess the deformation of the inlay, the smallest and the median diameter of the cup opening were measured using a 3 dimensional coordinate measuring machine (Multisensor, Mahr, Germany). Results. 90% of the explants showed signs of wear on the backside of the inlay. Another typical and so far not described alteration was collar fatigue in 68%. 38% of the inlays showed rim creep: Examples for Backside wear, collar fatigue and rim creep are illustrated in Fig. 1. 90% had a diameter of 32.1 mm or less, and even 46% had a diameter less than 32 mm. Discussion. The investigated design is at the lower limit of the allowed machining tolerance of the cup opening (32 + 0.1 mm) and has no additional clearance (which some manufacturers add). It seems that the inlays yield at the dome because of the viscoelastic properties of polyethylene and the open dome area of the attached screw ring. This leads to excessive wear at the dome area and it triggers a “brake drum” effect at the cup opening. Thereby torsional stresses at the implant bone interface increase which lead to failure of the implant. To avoid this type of failure, PE inlays should have enough clearance at the cup opening and the inlay should have dome contact to the closed metal shell

Introduction. Total knee arthroplasty (TKA) is a successful procedure for end stage arthritis of the knee that is being performed on an exponential basis year after year. Most surgeons agree that soft tissue balancing of the TKA is a paramount to provide a successful TKA. We utilized a set of retrieved lower extremities with an existing TKA to measure the laxity of the knee in all three planes to see if wear scores of the implants correlated to the laxity measured. This data has never been reported in the literature. Methods. IRB approval was obtained for the local retrieval program. Each specimen was retrieved after removing the skin, subcutaneous tissue and muscle from mid thigh to mid tibia. The femur, tibia and fibula were then transversely cut to remove the specimen for testing. Each specimen was then imaged using a flouroscopic imaging unit (OEC, Inc) in the AP, Lateral and sunrise views. These images were used to analyze whether there were any signs of osteolysis. Each specimen was mounted into a custom knee testing machine (Little Rock AR). Each specimen then was tested at full extension, 30, 60, and 90 degrees of flexion. At each flexion angle the specimen was subjected to a 10Nm varus and valgus torque, a 1.5Nm internal and external rotational torque and a 35N anterior and posterior directed force. Each specimen's implants were removed to record manufacturer and lot numbers. Polyethylene damage scores (Hood et al. JBMR 1983) were then calculated in the medial, lateral and backside of the polyethylene insert as well as on the medial and lateral femoral condyle. (Figure 1) Correlation coefficients were then calculated to show any relationship with soft tissue balancing in all three planes and wear scores. Results. No correlation > 0.4 existed for any surface damage on the polyethylene or femoral condyle to laxity in any plane (Figure 2). The highest correlations were found with backside wear (0.5) to internal and external rotational laxity. Two thirds of the specimens had more varus than valgus laxity in the coronal plane (p=0.03). Discussion/Conclusion. This is the first report of necropsy obtained retrievals where the soft tissue laxity of the knee was recorded. Although small numbers with different implant types the data shows that limited correlation exists between implant surface damage and increased laxity. The strongest correlation we found was backside wear to transverse plane laxity in flexion and extension, but this most likely is related to locking mechanism design. It seems in this set of implants that the soft tissue laxity did not affect implant bone interfaces as all were over 10 years from surgery. For figures/tables, please contact authors directly.

Intro: There are few modern reports which document the results of all-polyethylene tibial components in younger, more active patients. The potential benefits of this design are the elimination of backside wear and lower implant cost than modular, metal-backed components. From January 1992 to the present, 56 TKRs were implanted in 41 patients less than 60 years of age at the time of index surgery using a cemented all-poly tibial component with a PS design. Indications included all patients with osteoarthritis or post-traumatic arthritis without significant tibial bone loss. All patientswere followed prospectively with clinical and radiographic criteria asdefined by the Knee Society. Patient Assessment Questionnaires were used to quantify patient satisfaction, pain, and activity levels. From January 1992 to the present, 56 TKRs were implanted in 41 patients less than 60 years of age at the time of index surgery using a cemented all-poly tibial component with a PS design. Indications included all patients with osteoarthritis or post-traumatic arthritis without significant tibial bone loss. All patientswere followed prospectively with clinical and radiographic criteria asdefined by the Knee Society. Patient Assessment Questionnaires were used to quantify patient satisfaction, pain, and activity levels. Discussion: Since the mid 1980s, modular, metal-backed tibial trays have dominated the TKR market based on finite-element analysis studies which demonstrated superior force distribution compared to conventional all-poly components. As a result, backside wear has become an emerging problem and refocused design efforts on unitized components. Our clinical experience indicates an all-poly tibial component fixed with cement provides excellent performance and survivorship even in younger, more active patients