Total hip arthroplasty has seen a transition from cemented acetabular components to press-fit porous coated components. Plasma sprayed titanium implants are often press-fit with 1mm under-reaming of the acetabulum; however, as porous coating technologies evolve, the amount of under-reaming required for initial stability may be reduced. This reduction may improve implant seating due to lowered insertion loads, and reduce the risk of intraoperative fracture. The purpose of this study was to investigate the initial fixation provided by a high porosity coating (P2, DJO Surgical), and a plasma sprayed titanium coating under rim loading with line-to-line and 1mm press-fit surgical preparation. Five, 52mm high porosity acetabular cups (60% average porosity) and five 52mm plasma sprayed titanium coated cups were inserted into low density (0.24g/cc) biomechanical test foam (Pacific Research Laboratories). Foam test material was cut into uniform 90×90×40mm blocks. Reaming was performed using standard instrumentation mounted on a vertical mill. Cups were first inserted into foam blocks prepared with line-to-line (52mm) reaming. Following mechanical testing, cups were removed from the foam, cleaned, and inserted into foam blocks prepared with 1mm under reaming (51mm). In total 4 test conditions were evaluated:
Acetabular cup impaction was carried out using a single axis servohydraulic test machine (Instron 8500). Cups were inserted at 1mm/s to a load of 5kN. Insertion load was calculated as a 0.1mm offset from the linear portion of the force/displacement curve; insertion energy was the area under the curve. Tangential rim loading was applied at 0.0254mm/s by a conical indenter to the implant rim. Load data were recorded at 1kHz. Cup displacement was recorded by a 3D, marker-based tracking system at 15Hz (DMAS, Spicatek). Six markers were attached to a disk secured in the acetabular cup (Figure 1). Yield failure was defined as 0.331o of angular displacement (150µm of relative displacement). Angular displacement was derived by calculating the normal vector of a best-fit plane based on marker centroids.Introduction
Methods
Rotator cuff tears are common injuries which often require surgical repair. Unfortunately, repairs often fail [1] and improved repair strength is essential. P2 Porous titanium (DJO Surgical, Austin TX) has been shown to promote osseointegration [2,3] and subdermal integration [4]. However, the ability of P2Porous titanium to aid in supraspinatus tendon-to-bone repair has not been evaluated. Therefore, the purpose of this study was to investigate P2 implants used to augment supraspinatus tendon-to-bone repair in a rat model [5]. We hypothesized that supraspinatus tendon-to-bone repairs with P2 implants would allow for ingrowth and increased repair strength when compared to standard repair alone. Thirty-four adult male Sprague-Dawley rats were used (IACUC approved). Rats received bilateral supraspinatus detachment and repair with one limb receiving P2 implant. Animals were sacrificed at time 0 (n=3), 2 weeks (n=8), 4 weeks (n=9) and 12 weeks (n=14). Limbs were either dissected for histological and SEM analysis or mechanical testing as described previously [5]. Specimens for histology and SEM were embedded in PMMA for tissue-implant interface analysis. Specimens were first viewed in SEM under BSE to detect bony ingrowth, then stained with Sanderson's Rapid Bone Stain and viewed under transmitted and polarized light for tissue ingrowth. Comparisons were made using Student's t-tests with significance at p≤0.05.INTRODUCTION
METHODS
Over 40-years the dominant form of implant fixation has been bone cement (PMMA). However the presence of circulating PMMA debris represents a 3rd-body wear mechanism for metal-on-polyethylene (MPE). Wear studies using PMMA slurries represent tests of clinical relevance (Table 1). Cup designs now use many varieties of highly-crosslinked polyethylene (HXPE) of improved wear resistance. However there appears to be no adverse wear studies of vitamin-E blended cups.1–4 The addition of vitamin E as an anti-oxidant is the currently preferred method to preserve mechanical properties and ageing resistance of HXPE. Therefore the present study examined the response of vitamin-E blended liners to PMMA abrasion combined with CoCr and ceramic heads. The hip simulator wear study was run in two phases to compare wear with, (i) clean lubricants and (ii) PMMA slurries. The vitamin-e blended polyethylene liners (HXe+) were provided by DJO Surgical (Austin, TX) with 40mm CoCr and ceramic femoral heads (Biolox-delta). Polyethylene liners were run in standard “Inverted” test. (Table 1) All cups were run in ‘clean’ serum lubricant for 6-million load cycles (6Mc)5 and in a debris slurry (PMMA: 5mg/ml concentration) for 2Mc.4 A commercial bone cement powder was used as “abrasive” (Biomet, Warsaw, IN). PMMA slurries were added at test intervals 6, 6.5, 7 and 7.5Mc.4 Wear was assessed gravimetrically and characterized by linear regression. Bearing roughness was analyzed by interferometry and SEM.Introduction
Methods
Is is believed that 3rd-body wear of polyethylene, be it from particles of bone, bone-cement (PMMA), or metal, is an unavoidable risk in total hip arthroplasty (THA). Simulator studies have demonstrated that wear in conventional polyethylene (CXPE) and highly crosslinked polyethylene (HXPE) cups increased 6 and 20-fold respectively when challenged by circulating 3rd-body PMMA particulates. There was no corresponding change in head roughness, i.e. the PMMA did not roughen CoCr surfaces. Many contemporary cup designs now use the vitamin-E process combined with higher crosslinking dosage (VEPE). However, little if anything is known about the VEPE debris. Therefore in this study we analyzed the morphology of VEPE particles from cups that had been run in, a) standard simulator test mode and b) adverse PMMA debris-challenge mode. The aim of this study was to determine how a clinically relevant challenge, such as addition of PMMA particles affected the wear debris. This had not been attempted previously due to contamination polyethylene by PMMA debris. The hypotheses were that, a) during the ‘clean’ test, VEPE would yield smaller debris of standard globular shape compared to controls (XPE) and b) in adverse PMMA challenge mode, VEPE debris size would increase and become more flake-like. The XPE and vitamin-E blended cups (VEPE) cups were gamma-irradiated at 7.5 Mrad and 15 Mrad, respectively. Cups were run Inverted and mated with ceramic femoral heads of diameter 44 mm (Biolox-delta, Ceramtec). The three test phases included; ‘clean’ for 6 million cycles (6 Mc), abrasive slurry 6–8 Mc (concentration 10g/L), and ‘clean’ 8–10 Mc. The debris was isolated using standard procedure for ‘clean’ tests and a modified procedure for the abrasive slurries. Particles were imaged using SEM and the micrographs analyzed (Image J). Approximately 600 particles were analyzed from each sample (4.5 Mc and 8 Mc) and morphology defined via aspect ratio (AR), equivalent circular diameter (ECD), and circular shape factor (CSF). The clean test revealed slight differences in shape factors for XPE and VEPE (AR, CSF within 30%: p <0.0001) but none with regard to size (p > 0.9999). The median ECD for both XPE and VEPE was approximately 0.55 μm. The abrasive test revealed a statistical difference (p < 0.0001) in shape compared to the clean test, but varied less than 25%. The greater change in debris morphology between the abrasive test and clean test was size, which increased 3.6 fold for VEPE particles (ECD = 2.0 μm) and 4.3 fold for XPE particles (ECD = 2.3 μm). It was determined that addition of vitamin E to the PE did not change the size, but did change the shape of PE debris particles up to 30%. This study was the first to isolate debris particles during an abrasive slurry test and determine morphology under such conditions. Debris particles formed in abrasive conditions were found to be 4-fold larger in diameter, suggesting a larger volume of shreds in comparison to the mostly submicron population observed under standard testing conditions. Figure 1: Boxplot of equivalent circular diameter values. Figure 2: Boxplot of aspect ratio values. Figure 3: Boxplot of circular shape factor values.
The clinical outcome and radiographic analysis of 82 patients undergoing total hip arthroplasty using a titanium acetabular component coated with a new proprietary Titanium Porous Coating inserted without cement are reported. All total hip replacements were performed by a single surgeon and utilized a porous coated, cementless femoral component. Pre clinical testing was carried out in an animal model to evaluate the new porous coating. THR was performed using a cementless acetabular component of the same geometrical design inserted without cement. The component is coated with a new proprietary Titanium Porous Coating wherein the non-spherical bead itself is also porous. This creates a “lava rock” type of structure and gives variability in the pore sizes that aids in the in-growth and apposition of bone (fig 5). The inter-bead pore size: the pore size between each non-spherical bead = 200–525 μm while the Intra-bead pore size: the pore size within each non-spherical bead = 25–65 μm. The resulting surface is extremely rough and provides a robust initial “bite” or “stick” to the bone. Clinical results were evaluated using the Harris Hip score and were recorded prospectively preoperatively and at 6 weeks, 6 months, and 1 year postoperatively. Radiographs were evaluated for component migration, subsidence, and cortical and cancellous biologic response as well as zonal analysis of radiolucent lines, using the Muller THR template. Pre-clinical animal testing of the new porous coating was carried out in 50 sheep using a metacarpal intramedulary implant (similar to a hip stem) designed to function as a Percutaneous Osseointegrated Prosthesis (POP) for amputees and evaluated Apposition Bone Index (ABI) (fig 1), Mineral Apposition Rate (MAR) (fig 2),% Bone In-growth (fig 3), and Axial Pull-out Force (fig 4). Sheep were sacrificed at time points of 0, 3, 6, 9, and 12 months to measure and evaluate the above parameters. Human clinical and radiographic follow up averaged 10.5 months (range 2–18 months). There were 39 females and 43 males. Average age was 59 years. The clinical results were excellent with respect to both pain and function at mid term follow up. Patient satisfaction was high. Radiographic analysis showed no migration or change in the angle of inclination at latest follow up. Femoral component subsidence was detected in 2 cases and averaged 1.8 mm. No polyethylene wear was detected. No hips dislocated. No hips underwent additional surgery. Pre-clinical test data demonstrated excellent mechanical and biological attributes. Average tensile strength of the coating surpassed the FDA minimum requirement by 3X. Animal testing in the sheep showed no evidence of stem loosening or need for revision after 12 months, and corroborated well with clinical results. Correlation between the pre-clinical testing and the human experience was exceptional. Application of a new titanium porous coating utilizing a proprietary dual pore size structure to the surface of the acetabular component provides an extremely rough surface and robust initial fixation during cementless THR. Excellent early clinical and radiographic results are demonstrated. The addition of this new type of porous coating to other arthroplasty components may confer additional clinical advantages.
Periprosthetic infections that accompany the use of total joint replacement devices cause unwanted and catastrophic outcomes for patients and clinicians. These infections become particularly problematic in the event that bacterial biofilms form on an implant surface. Previous reports have suggested that the addition of Vitamin E to ultra-high-molecular-weight polyethylene (UHMWPE) may prevent the adhesion of bacteria to its surface and thus reduce the risk of biofilm formation and subsequent infection.1–3 In this study, Vitamin E was blended with two types of UHMWPE material. It was hypothesized that the Vitamin E blended UHMWPE would resist the adhesion and formation of clinically relevant methicillin-resistant Five sample types were manufactured, machined and sterilized (Table 1). To determine if MRSA biofilms would be reduced or prevented on the surface of the Vitamin E (VE) loaded samples (HXL VE 150 kGy and HXL VE 75 kGy) in comparison to the other three clinically relevant material types, each was tested for biofilm formation using a flow cell system.4
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