Today's aging society is seeing an increase of patients with rheumatoid arthritis and osteoarthritis, as well as an increase in joint replacement surgery. The artificial joints used in this surgery frequently uses ultra-high molecular weight polyethylene (UHMWPE) as a bearing material. However, UHMWPE wear particles are considered to be a major factor in long-term osteolysis, and implant loosening. Many researchers have reported that the volume and size of particles are critical factors in macrophage activation, with particles in the size range of 0.1 – 1.0 μm being the most biologically active. The micro slurry-jet erosion (MSE) apparatus was introduced to minimize the amount of wear, and increase the size of UHMWPE wear particles by texturing the surfaces of Co-Cr-Mo alloy implants. The MSE apparatus uses a slurry of alumina particles (WA#8000: average diameter 1.2 μm) mixed with water. The slurry and compressed air are mixed within an injection nozzle, which is then applied to the Co-Cr-Mo alloy at high speed to achieve a desired nano-textured surface. In this study, four Co-Cr-Mo alloy surface profiles were prepared. The MSE injection nozzle was fed 40.0 mm in alternating directions across each surface with an orthogonal step of 0.5 mm. The surface M-1 was processed with an injection nozzle feed rate of 1.0 mm/s, and obtained a surface roughness of 5.7 nm. M-2 was processed with a feed rate of 2.0 mm/s, and had a surface roughness of 2.3 nm. The M-4 surface used a 40.0 mm alternating directions surface feed, but with a 1.0 mm orthogonal step, and an injection nozzle feed rate of 0.5 mm/s. It obtained a surface roughness of 4.0 nm. The G-1 surface, with a roughness of 10.0 nm, was processed with the typical lapping method, which is used in conventional artificial joints [Fig. 1]. A pin-on-disk wear tester, capable of multidirectional motion, was used to assess which surface was the most appropriate for artificial joints. The UHMWPE pins were flat ended cylinders, 12.0 mm in diameter, and were placed on the disk with a contact pressure of 6.0 MPa. Tests were carried out in 25% (v/v) fetal calf serum with sodium azide to retard bacterial growth. A sliding speed of 12.1 mm/s, and a total sliding distance of 15.0 km were applied. The wear weight of the MSE textured surface M-1 was significantly lower than the wear weight of the conventional surface. Moreover, the percentages of various wear particle sizes obtained from MSE surface texturing was significantly different from those obtained from the traditional surface.

Cases of intertrochanteric hip fractures as a result of osteoporosis have been increasing in recent years. Treatment of these types of fractures is often performed with intramedullary (IM) nails or compression hip screws (CHS) ^[1]. IM nails are composed of a stem, which is inserted into the medullary canal of the femur, and a lag screw that is placed inside the head of the femur. One problem with this type of device is that both the left and right femurs are fixed with IM nails that have right-hand threaded lag screws. Therefore, on left femurs, the right-handed threads may not provide satisfactory fixation in the bone. This insufficient fixation could cause rotary motion and slippage in the femoral head, which would inhibit fracture healing. This study used three-dimensional finite element analysis (FEA) to examine the fixation and rotational characteristics in reference to the thread direction of the lag screw and the relative angle between the stem and lag screw.

In this study, a 3D CAD model of a left femur and four proximal femoral IM nail designs were analyzed in FEA for stress and displacement. An intertrochanteric femoral fracture was created so that the femoral head and diaphysis were separated. The four IM nails were designed to with either left or right-handed lag screw threads (figure .1) and with relative stem-lag screw angles of 125 or 135 degrees. (Traditional IM nails use a right-handed screw and a relative angle of 125 degrees.)

The results showed the femoral head displacement was smaller when using the left-handed lag screw. It is thought that this difference between the left and right-handed screws is caused by the direction of rotation, which would cause the left-handed screw to tighten and the right-handed screw to loosen within the femoral head. The femoral head displacement also decreased with a screw-stem angle of 135 degrees in comparison to the standard 125 degree angle. The standard right-handed screw with 125 degree relative angle was shown to have the largest displacement of all four types of tested IM nails, whereas the left-handed, 135 relative degree design produced the smallest displacement of all four implants.

These results show how using a left-handed lag screw with proper relative angles in the left femur, effectively reduces femoral head displacement when compared to traditional right-handed lag screw IM implants. This is important for the promotion of intertrochanteric fracture healing.

This study presents the use of precision surface machining on artificial joint bearing surfaces in order to inhibit macrophage activation. Ultra-high molecular weight polyethylene (UHMWPE) is widely used as a bearing material in polymer-on-hard joint prostheses. However, UHMWPE wear particles are considered to be a major factor in long-term osteolysis and implant loosening. Several studies report that wear particle size is a critical factor in macrophage activation, with particles in the size range of 0.1 – 1.0 μm being the most biological active. The surface for a conventional Co-Cr-Mo alloy joint implant generally has a 10.0 – 20.0 nm roughness. After precision machining, the Co-Cr-Mo alloy surface had a 1.0 – 2.0 nm roughness with scattered concave shapes up to 50 nm in depth. This precision surface machining method used a typical lapping method, but the relationship between the slurry and the machining surface was strictly controlled in order to emphasize the micro-erosion mechanism. A pin-on-disc wear tester capable of multidirectional motion was used to verify that the new surface was the most appropriate for joints. Tests were carried out in 25% (v/v) fetal calf serum with sodium azide to retard bacterial growth. UHMWPE pins, 12.0 mm in diameter with a mean molecular weight of 6.0 million, were placed on the Co-Cr-Mo alloy disc at a contact pressure of 6.0 MPa. A sliding speed of 12.1 mm/s, and a total sliding distance of 15.0 km were applied. The new surface reduced the amount of UHMWPE wear, which would ensure the long-term durability of joints. The new surface also enlarged the size of UHMWPE particles, but did not change their morphological aspect. Primary human peripheral blood mononuclear phagocytes were cultured with the particles. The wear particles generated on the new surface inhibited the production of IL-6, which indicates a reduction of induced tissue reaction and joint loosening.

An ultra-high molecular weight polyethylene (UHMWPE) is widely used as bearing material in artificial joints, however, UHMWPE wear particles are considered to be a major factor in long-term osteolysis and loosening of implants. The wear particles activate macrophages, which release cytokines, stimulating osteoclasts, which results in bone resorption. The biological activity of the wear debris is dependent on the volume and size of the particles produced. Many researchers reported that the volume and size of particles were critical factors in macrophage activation, which particles in the size range of 0.1–1 mm being the most biological active.

To minimize the amount of wear of UHMWPE and to enlarge the size of UHMWPE wear particle, a nano-level surface textured on Co-Cr-Mo alloy as a counterface material was invented (Figure 1). Although the generally-used surface for a conventional artificial joint has 10 nm roughness (G-1), the nano-level surface has a superfine surface of 1 nm with groove and dimples against the bearing area. The existence probability of groove or dimples, and their surface waviness were adjusted (P-1, 2, 3, 4 and W-1, 2).

Pin-on-disc wear tester capable of multidirectional motions was used to verify that the nano-textured surface is the most appropriate for artificial joint. UHMWPE pin with an average molecular weight of 6.0 million was placed in contact with the disc and the contact pressure was 6.0 MPa. The disc and pin were lubricated by a water-based liquid containing the principal constituents of natural synovial fluid. Sliding speed of 12.12 mm/s had been applied for total sliding distance of 15 km.

The nano-textured surfaces reduced the amount of UHMWPE wear, this would ensure the long-term durability of artificial joint (Figure 2). The wear particles isolated from lubricating liquid were divided broadly into two categories; one is “simple type” and the other is “complicated type”. The lengths in a longitudinal direction (L_l) and its orthogonal direction (L_s) for each particles (>150) were measured, and the each aspect ratio (= L_l/L_s) was calculated. No significant difference was found in the ratio between simple type and complicated type, and in the distributions of aspect ratios. However, the distributions of L_l, which means the size of UHMWPE wear particle, were dramatically changed by using the nano-textured surface (Figure 3). These results suggest that the nano-textured surface does not change the morphological aspect of UHMWPE particle but enlarges the size of UHMWPE particle.

Cells (RAW264.7, blood, Mouse) were cultured with the particles in supplemented Dulbecco's modified Eagle's medium for 24 h in an atmosphere of 5% CO₂ in air at 37 degrees C, and the quantitative PCR was performed for genetic expression of IL-6. The wear debris generated on the nano-textured surface inhibited the genetic expression of IL-6, which does not induce the tissue reaction and joint loosening.

An ultra-high molecular weight polyethylene (UHMWPE) is widely used as bearing material in artificial joints, however, UHMWPE wear particles are considered to be a major factor in long-term osteolysis and loosening of implants. The wear particles activate macrophages, which release cytokines, stimulating osteoclasts, which results in bone resorption. The biological activity of the wear debris is dependent on the volume and size of the particles produced. Many researchers reported that the volume and size of particles were critical factors in macrophage activation, which particles in the size range of 0.1–1 mm being the most biological active.

To minimize the amount of wear of UHMWPE and to enlarge the size of UHMWPE wear particle, a nano-level surface texturing on Co-Cr-Mo alloy as a counterface material was invented. Although the generally-used surface for a conventional artificial joint has 10 nm roughness (Surface A), the nano-level textured surface invented has a superfine surface of 1 nm with 3% of groove and dimples against the bearing area. The depths of groove and dimples are less than 50 nm (Surface F).

Pin-on-disc wear tester capable of multidirectional motions was used to verify that the nano-textured surface is the most appropriate for artificial joint. UHMWPE pin with an average molecular weight of 6.0 million was placed in contact with the disc and the contact pressure was 6.0 MPa. The disc and pin were lubricated by a water-based liquid containing the principal constituents of natural synovial fluid. Sliding speed of 12.12 mm/s had been applied for total sliding distance of 15 km.

The superfine surface with nano-level grooves and dimples (Surface F) reduced the amount of UHMWPE wear, this would ensure the long-term durability of artificial joint. The wear particles isolated from lubricating liquid were divided broadly into two categories; one is “simple type” and the other is “complicated type”. The lengths in a longitudinal direction (L_l) and its orthogonal direction (L_s) for each particles (>150) were measured, and the each aspect ratio (= L_l/L_s) was calculated. No significant difference was found in the ratio between simple type and complicated type, and in the distributions of aspect ratios. However, the distributions of L_l, which means the size of UHMWPE wear particle, were dramatically changed by using the nano-textured surface (Figure 2). These results suggest that the nano-textured surface does not change the morphological aspect of UHMWPE particle but enlarges the size of UHMWPE particle.

Cells (RAW264.7, blood, Mouse) were cultured with the particles in supplemented Dulbecco's modified Eagle's medium for 24 h in an atmosphere of 5% CO₂ in air at 37 degrees C, and the quantitative PCR was performed for genetic expression of IL-6 (Figure 3). The wear debris generated on the nano-textured surface inhibited the genetic expression of IL-6, which does not induce the tissue reaction and joint loosening.

An artificial articular cartilage is being investigated for use in joint replacement. The low elastic modulus lining on the bearing surface is used to promote a continuous lubricant film between the articulating surfaces and hence reduce both friction and wear.

Polyvinyl formal (PVF) as an artificial articular cartilage was proposed to prolong the service life of joint replacement. The major raw material of the PVF was a polyvinyl alcohol (PVA) hydrogel, which was one of the few polymers with hydrophilic properties. It is anticipated to realize a wide range of clinical applications due to its high water-holding capacity and high biocompatibility. However, a major problem with PVA hydrogel is its low wear resistance. The PVF was made by performing a chemical cross-linking reaction in PVA, and its pore diameter, porosity, and beam density could be controlled by varying the concentrations of cross-linking agent (formaldehyde) and catalyst (sulfuric acid).

The knee joint simulator was used for investigating the wear performance of the PVF. The load and motion cycles were taken from ISO 14243-3. The peak load was 2.6 kN, and the walking cycle was 1.0 seconds. The lower PVF specimen represented the flat tibial component of the joint, and the femoral component was artificial knee joint which made from Co-Cr-Mo alloy. The lubricant was a waterbased liquid containing the principal constituents of synovial fluid.

The PVF survived for more than 1.0 million cycles. Enlargement of the PVF creep deformation by prolongation of simulating time was not obvious. Although the tribological property in fatigue wear produced by ploughing friction was inadequate, it was obvious that the PVF was a potential material for developing a load bearing system with hydration lubrication.

Polyethylene wear in total knee arthroplasty (TKA) is a complex and mutifactorial process. It is generally recognized that wear is directly related to a material wear factor, contact stress, and sliding distance. Conventional methods of predicting polyethylene wear in TKA mainly focus on peak contact stress or subsurface shear stress using finite element method analysis. By incorporating kinematics and contact stress, a new predictor for polyethylene wear in TKA (“Wear Index”) has been developed. The Wear Index was defined by multiplying deformation by femoro-tibial sliding velocity. The purpose of this study was to determine the predictive value of the Wear Index for polyethylene wear in TKA using both a numeric and an in vitro model.

Four commercially available total knee prostheses were modeled for this study. Deformation and sliding velocity were calculated based on the three-dimensional geometry of the components and the gait kinematic inputs using Hertz’s formula. One specimen of each of the four types of total knee prostheses was mounted on a custom-designed knee simulator. Vertical loads and flexion-extension uni-axial motion were simulated using computer controlled servohydraulic actuators. The same gait kinematic inputs used in the theoretical study were used in the simulation test. After the simulations, the surface of the tibial insert was examined microscopically and macroscopically and compared with the theoretically generated Wear Index.

This study showed a high correlation between the numeric model and the simulation. The depth of wear on the tibial insert correlated significantly with the Wear Index. Microscopic findings also demonstrated a good correlation between the Wear Index and observed wear patterns. Sliding velocity is an important factor for understanding wear in TKA. In conclusion, this study suggests that the Wear Index is a reliable predictor of polyethylene wear in TKA, as it incorporates both contact stress and kinematics in its calculation.

Flexion after total knee arthroplasty (TKA) has recently been improved by changing implant designs, surgical techniques and early postoperative rehabilitation protocols. Especially for Asian people, deep knee flexion is essential because of their life style. Small numbers of patients can achieve full flexion after TKA, however, most current prostheses are not designed to allow deep knee flexion safely. Furthermore, the kinematics involved in knee flexion greater than 90 degrees in cases of TKA is still unknown, even though fluoroscopic studies have shown the paradoxical anterior femoral translation in posterior cruciate retaining (CR) TKA with knee flexion up to 90 degrees. The purpose of this study was to determine the femoro-tibial contact pattern in deep knee flexion.

The knee that had been operated upon was passively flexed from 90 degrees up to the maximum flexion under anesthesia soon after the surgery. Lateral roentgenograms of the knee were taken during flexion, and the three-dimensional kinematics was analyzed using image-matching techniques. Nine patients with CR type were included.

The average maximum flexion angle was 131.8 °. The contact point moved posteriorly with deep knee flexion except for one patient. Five out of nine patients showed external rotation of the femoral condyle. Two patients showed internal rotation, and the other two exhibited no rotational movement. None of the patients showed dislocation or disengagement of the components. At the maximum flexion, the edge of the posterior flange of the femoral component contacted the polyethylene insert.

This study was performed under non-weight-bearing conditions, but deep knee flexion is not usually performed in weight-bearing conditions. Most of the CR type showed posterior roll back during deep knee flexion. The design of the posterior flange of the femoral component should be changed to prevent damage to the polyethylene.