The overtightening of cancellous surgical screws is a major problem for orthopaedic surgeons, especially inexperienced ones. This problem is made worse still when the patient suffers from osteoporosis, which significantly reduces the density of the bone. Overtightening a screw leads to stripping of the bone and potential complications to surgery leading to increased recovery time and potential expense to the health organisation. Acoustic Emission (AE) has previously been investigated to monitor the insertion of such screws into artificial Sawbones. This paper presents the testing of two sizes of surgical screws into both artificial Sawbones and cadaveric femurs monitored for AE using piezoelectric sensors. The results show that there are some significant differences between the AE given off from the two structures when the energy and frequency of the waveforms are analysed.

Background: To develop experience, orthopaedic surgeons train their own proprioception to detect torque during screw insertion. This experience is acquired over time and when implanting conventional/non-locked screws in osteopenic cancellous bone the experienced surgeon still strips between 38 and 45%. Technology needs to be investigated to reduce stripping rates. Acoustic-Emission technology has the ability to detect stress wave energy transmitted through a screw during insertion into synthetic bone. Our hypothesis is Acoustic-Emission waves can be detected through standard orthopaedic screwdrivers while advancing screws through purchase and overtightening in cancellous human bone with different bone mineral densities replicating the clinical state. Methods: 77 non-locking 4 mm and 6.5 mm diameter cancellous bone screws were inserted through to stripping into the lateral condylar area of 6 pairs of embalmed distal femurs. Specimens had varying degrees of bone mineral density determined by quantitative CT. Acoustic-Emission energy and axial force were detected for each test. Results: The tests showed a significant high correlation between bone mineral density and Acoustic-Emission energy with R = 0.74. A linear regression model with the mean stripping load as the dependent variable and mean Acoustic-Emission energy, bone mineral densities and screw size as the independent variables resulted in r(2) = 0.94. Interpretation: This experiment succeeded in testing real time Acoustic-Emission monitoring of screw purchase and overtightening in human bone. Acoustic-Emission energy and axial compressive force have positive high correlation to bone mineral density. The purpose is to develop a known technology and apply it to improve the bone-metal construct strength by reducing human error of screw overtightening.

BACKGROUND: Fresh frozen human femurs are considered "the gold standard" in biomechanical studies of hip fractures, resembling the in vivo situation mostly. A more readily available alternative is formalin embalmed femurs. However, to which extent formalin affects key features of bone; its mechanical properties, bone mineral content and their mutual relationship over time, remains unknown. Accordingly, we measured the mineral parameters and related them to the mechanical properties of formalin fixed femurs after long-term storage. METHODS: 36 paired femurs from human donors, fixed in formalin and stored for a mean period of 4.6 (3.5-6) years. Quantitative CT was performed to measure the bone mineral density and mass at the mainly cortical mid shaft and the center of the mainly cancellous condyles. Each pair was subjected to local tests by three-point bending and screw pullout of the shaft and lateral punch and metaphyseal cube compression of the condyles. FINDINGS: Neither mechanical nor bone mineral data were significantly correlated to storage time. Well-known associations for bone parameters with age and gender were retrieved. Maximum force of the cortical bone tests was highly correlated to the diaphyseal bone mass; (r = 0.80-0.87, p = 0.01), while maximum force of the cancellous bone tests correlated well to the density of the condylar bone; (r = 0.70, p = 0.01). INTERPRETATION: Our results indicate that mechanical and bone mineral data and their mutual relationship are conserved in formalin fixed femurs even after long-term storage. Formalin fixed femurs may serve as an alternative to fresh frozen femurs in biomechanical testing.

A preliminary study of acoustic emission during orthopaedic screw fixation was performed using polyurethane foam as the bone-simulating material. Three sets of screws, a dynamic hip screw, a small fragment screw and a large fragment screw, were investigated, monitoring acoustic-emission activity during the screw tightening. In some specimens, screws were deliberately overtightened in order to investigate the feasibility of detecting the stripping torque in advance. One set of data was supported by load cell measurements to directly measure the axial load through the screw. Data showed that acoustic emission can give good indications of impending screw stripping; such indications are not available to the surgeon at the current state of the art using traditional torque measuring devices, and current practice relies on the surgeon’s experience alone. The results suggest that acoustic emission may have the potential to prevent screw overtightening and bone tissue damage, eliminating one of the commonest sources of human error in such scenarios.

for example dental rolls, but we feel that it provides useful information regarding ‘tissue’ handling as every grip is apparent on the model, and can therefore be used by the trainer as a way of evaluating the trainee. A more forceful grip will lead to the tearing of the silicon, and the path of the needle is easily seen within the tendon. We recommend this silicone model as a simple and accessible training tool for all hand and plastic surgery trainees, as a means of learning the correct suture configurations in the various repairs.