Osteolsyis is one of the main reasons for revision of total joint replacements. The osteolytic reaction is influenced by dose, size (particles < 1μm are believed to be biologically more active) and shape of wear particles, so that low wear rates and biologically less active particles are required.

In addition, in the knee a range of design and kinematic variables have to be considered as they can markedly influence wear regardless of the type of polyethylene used. Furthermore, UHMWPE (ultra-high-molecular-weight-polyethylene) fatigue occurs more frequently in the knee joint than in the hip joint due to its changing tribocontact areas combined with high weight bearing. This is why crosslinked polyethylene (XPE) is still controversially discussed for use in total knee prostheses.

Question: Is XPE appropriate for both fixed- and mobile-bearing knee prostheses? Are XPE-particles different from UHMWPE-particles?

Method: In a knee-joint-simulator (Stallforth-Ungeth-uem) 4 XPE (1 sequential irradiated/annealed, 3 different remelted, fixed- and mobile-bearing-types) and 2 UHMWPE-inserts (fixed- and mobile-bearing) were tested (ISO). The gravimetric wear rates (mg/year) were measured (5mill. cycles), the wear mechanism was analysed by scanning electron microscope (SEM). Furthermore, 100.000 particles were analysed by SEM (20nm-nucleo-pore-filter;acid digestion method;ISO) in size and shape.

Results: All the inserts showed traces of abrasion, scratching and wear polishing. XPEs produced lower wear rates (range 0,6–4,3mg/year;p< 0,05) than UHM-WPEs (range 8,4–8,5mg/year) in fixed- as well as mobile-bearing knee prostheses without fatigue reactions. The sequentially irradiated and annealed insert showed the lowest wear rate (0,6mg/year;p< 0,05) overall. For all the groups the particles were smooth, granular, irregular and less fibrillar and more than 85% of the particles were submicron. The particle size was independent of the radiation dose. Fixed-bearings produced a larger amount of particles < 1μm (93,2–96,3%;p< 0,05) than mobile-bearings (85,5–89,5%).

Conclusion: All crosslinked tibial inserts, fixed- as well as mobile-bearings, showed statistically significant (p< 0.05) reduced wear rates without any fatigue reactions. The fixed-bearing sequential irradiated and annealed insert had the lowest wear rate (p< 0.05). XPEs (fixed- and mobile-bearings) and UHMWPEs have similar wear particles in shape. The particle size was independent of the radiation dose, but most of the particles are in the biologically more active range of size (fixed> mobile-bearing). Due to this further investigation with in-vivo-models is required.

Periprosthetic osteolysis, caused in a chronic inflammatory adverse reaction to wear particles in the surrounding tissues, is one of the major reasons for revision arthroplasty so that articulating surfaces with low wear rates are required. Compared with conventional ultra high molecular weight polyethylene (UHMWPE), highly crosslinked polyethylene (HXLPE) shows a reduced wear rate in a hip simulator. The crosslinking process which is achieved by gamma or electronic radiation, followed by heat treatment either above the melting point (remelting) or below (annealing), reduces the mechanical properties of UHMWPE, particularly its fatigue strength. UHMWPE fatigue occurs more frequently in the knee than in the hip due to its higher contact stresses. This is why HXLPE is still controversially discussed for use in total knee prostheses. We have examined the wear behaviour of different HXLPEs [one cruciate-retaining (CR; sequential irradiation and annealing), one ultra-congruent (remelting), one CR (remelting)], compared with conventional UHMWPE in a knee simulator (Stallforth-Ungethuem). In the fixed bearing knee recommended from the manufacturer the wear rates [gravimetric (mg/year); volumetric (mm³/year)] were determined according to the ISO standard and the wear mechanism was analysed by means of a scanning electron microscope.

All insert showed signs of abrasion, scratching and wear polishing, but no traces of fatigue reactions. All HXLPEs produced lower (p< 0.05) wear rates (0.47–3.3 mg/year; 0.5–3.5 mm3/year) than the UHMWPE (8.1–9.1 mg/year; 8.6–9.7 mm3/year), the inserts of HXLPE manufactured by sequential irradiation and annealing showed the lowest wear rates (p< 0.05) overall.

Due to the reduced wear rates without any fatigue symptoms, we conclude that HXLPE is suitable for total knee prostheses and a monitored clinical investigation can be recommended. HXLPE manufactured by sequential irradiation and annealing seems to produce still lower wear rates than those manufactured by remelting, at least when used in total knee prostheses.