Recently, it has been reported that the posterior stabilised implant clinically used for the total knee replacement (TKR) may have a risk of failures caused by pressure and stress concentrated on the tibial post. Malalignment of the implant or variable loading applied to the implant are one of the major causes of the failure in posteriori stabilised TKR. The purpose of this study is to biomechanically analyse the effect of implant malalignment on the failure risk of the implant in posteriori stabilised TKR by estimating von-Mises stress on the implant.

Finite element models of a knee joint and a posteriori stabilised implant were developed from 1mm slices of CT images and 3D CAD software, respectively. The posterior stabilised implant consists of a femoral component, a tibial post, and a tibial tray. The finite element models of TKR for the neutral alignment case as well as the different malalignment cases (3° and 5° of valgus and varus angulations, 2° and 4° of anterior and posterior tilts, and 3° of external rotation) were developed. Then, the von-Mises stress, which is which was chosen as the fracture risk parameter, acting on the implant were analysed by using CAE software. Loading condition at the 40% of one whole gait cycle such as 2000N of compressive load, 25N of anterior-posterior load, and 6.5Nm of torque was applied to the TKR models.

The maximum von-Mises stresses were concentrated on the anterior region of the tibial post regardless of the oblique loadings. In the rotationally additional loading (3° of external rotation), excessive stresses occurred in the anterior medial and posterior lateral areas. The maximum stress was 18.3MPa in neutral position. The maximum stress increased by 10% in anterior tilt 2°, 15% in anterior tilt 4°, 25% in posterior tilt 2°, 54% in posterior tilt 4°, 116% in varus 3°, 262% in varus 5°, 318% in valgus 3°, 389% in valgus 5°, 6% in external rotation 3° compared with that in the neutral position case. In addition, 32.0MPa of maximum stress occurred on the posterior lateral area of the base component in rotationally additional loading.

The results showed that the implant malalignment could accelerate the stress concentration on the anterior region of the tibial post as in the result of clinical study. In the case of additional rotation, high stress concentration on the anterior medial and posterior lateral areas as well as on the tibial base surface could generate wear or fracture of tibial post. From the additional rotation case, we can expect that higher conformity implant will generate higher stress concentrations than lower conformity implant even though we did not compare the effect of conformity ratio on the stress concentration in the tibial polyethylene component. This study showed that careful consideration of the implant malalignment would be necessary to improve the clinical outcome in the posteriori stabilised TKR.