Abstract
Introduction
Retrieval investigations have shown that cracking or rim failure of polyethylene hip liners may occur at the superior aspect of the liner, in the area that engages the locking ring of the shell1. Failure could occur due to acetabular liner/stem impingement and/or improper cup position. Other contributing factors may include high body mass index, patient activity and design characteristics such as polyethylene material properties, thin liner rim geometry and cup rim design. Currently no standard multi-axis simulator methodology exists for high angle rim fatigue testing, although tests have been developed using static uniaxial load frames2. The purpose of this study was to develop a technique to create a clinically relevant rim crack/fracture event on a 4-axis hip simulator, and to understand the contribution of component design and loading and motion parameters.
Method
A method for creating rim fracture in vitro was developed to evaluate implant design features and polyethylene liner materials. Liners were secured into acetabular shells, fixtured in resin mounted at a 55° (in vitro; 65° in vivo) inclination to ensure high load/stress was at the area of interest. Ranges of kinematic and maximum applied load profiles were investigated (parameters summarized in Table 1). Testing was conducted on an AMTI 12-station hip simulator for 0.25–1.0 million cycles or until fracture (lubrication maintained with lithium grease). At completion, liners were cleaned and examined for crack propagation/fracture. Inspection of the impingement site on the opposite rim was also analyzed. Additional assessments included liner disassociation/rock out, deformation of characteristics such as anti-rotation devices and microscopic inspection of high-stress regions.
Results/Discussion
This study summarizes testing on hip wear simulators to create rim cracking/fracture in vitro. Results indicate that cup/stem angles must be controlled to ensure contact areas are reproducible, and therefore on a multi-station machine (i.e. AMTI), only one test station can/should be run at a time to ensure repeatability. Component design characteristics, such as head size and liner material had a marked effect on the results. It is noted that the kinematics, load and cycle count must be adjusted per the component design to create rim fracture in the high-risk region. Finite element analysis modeling may help identify the high-stress region(s) prior to simulator testing. Deformation of the rim opposite the fracture region (rim/taper impingement) was observed due to the high angle of inclination combined with the abduction/adduction angles.
Conclusion
Rim fractures similar in location and morphology to those seen in retrieval studies can be created using a multi-axis hip simulator in vitro. It is noted, however, that the factors presented in this study must be considered and controlled to assure a repeatable method, as the differences in component design investigated and simulator inputs were seen significantly affect the outcome. This study was limited and did not attempt to reproduce rim damage seen in all implant retrievals (e.g. lateralized liners, high offset implants, etc.). These design inputs are being investigated and will be reported upon in the future.
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