This study examines the resection surface geometry of the femur, tibia, and patella in relation to the design of total knee implants. Using a technique known as principal component analysis (PCA), the variation in the resection geometry of the knee was summarized. Of the total variation of the knee, 58 per cent was due to variation in size and 14 per cent was due to varying femoral intercondylar notch width. A PCA was performed on each bone separately and it was found that 60 per cent, 76 per cent and 71 per cent of variation was due to size for the femur, tibia, and patella respectively. Femoral and tibial size were highly correlated (r = 0.95) while patellar size had poorer correlation with both femoral and tibial size (r < 0.7). Simple linear dimensions (femoral epicondylar width or tibial mediolateral width) were reliable indicators of knee size. The effect of shape variation, which is generally not accounted for in implant design, was measured. The resected surfaces of each subject were compared with a model of the resection surfaces of the knee which varied in size but not shape. The maximum overhang and underhang of the model on the resection surfaces were measured. There was average maximum model overhang of 3.6 mm and underhang of 3.9 mm in the femur, 2.3 mm overhang and 1.9 mm underhang in the tibia, and 2.6 mm overhang and 2.5 mm underhang in the patella. The maximum coverage that an implant can be expected to provide for a population is quantified. Implant designs which include some shape as well as size variation improve on the implant fit.

Debris-induced osteolysis due to surface wear of ultra high molecular weight polyethylene (UHMWPE) bearings is a potential long-term failure mechanism of total knee replacements (TKR). This study investigated the effect of prosthesis design, kinematics and bearing material on the wear of UHMWPE bearings using a physiological knee simulator. The use of a curved fixed bearing design with stabilised polyethylene bearings reduced wear in comparison to more flat-on-flat components which were sterilised by gamma irradiation in air. Medium levels of crosslinking further improved the wear resistance of fixed bearing TKR due to resistance to strain softening when subjected to multidirectional motion at the femoral-insert articulating interface. Backside motion was shown to be a contributing factor to the overall rate of UHMWPE wear in fixed bearing components. Wear of fixed bearing prostheses was reduced significantly when anterior-posterior displacement and internal-external rotation kinematics were reduced due to decreased cross shear on the articulating surface and a reduction in AP displacement. Rotating platform mobile bearing prostheses exhibited reduced wear rates in comparison to fixed bearing components in these simulator studies due to redistribution of knee motion to two articulating interfaces with more linear motions at each interface. This was observed in two rotating platform designs with different UHMWPE bearing materials. In knee simulator studies, wear of TKR bearings was dependent on kinematics at the articulating surfaces and the prosthesis design, as well as the type of material.

This study evaluated the wear performance of conventional (gamma irradiation at 4Mrads in low oxygen) and moderately crosslinked (gamma irradiation at 5Mrads and melt-annealed) ultra high molecular weight polyethylene (UHMWPE) materials in fixed and mobile knee bearing designs. Kinematic and load inputs corresponding to the gait cycle outlined in the ISO displacement controlled knee simulation draft standard, ISO/CD 14243-3, were maintained in all simulations. Wear rates were determined gravimetrically. Surface finish changes and worn surface characteristics were also noted. Moderately crosslinked fixed bearing knee component wear rate was 74% lower than conventional fixed bearing components. There was no discernable difference in wear rate for the mobile bearing knee for the two materials. However, the mobile bearing knee wear rates were 94% and 79% lower than fixed bearing conventional and fixed bearing moderately crosslinked materials, respectively. In the fixed bearing knee, the majority of the wear reduction of the moderately crosslinked material compared to the conventional material was attributed to enhanced crosslinking due to the melt-annealing process rather than the dose difference. The reduction in wear rate of the mobile bearing knee compared to the fixed bearing was attributed to the reduced cross shear motion at the tibio-femoral articulation since mobile bearing wear was independent of material.

The performance of two knee simulators designed by ProSim (Manchester, UK) was evaluated by comparison of the wear seen in the press-fit condylar (PFC) Sigma (DePuy) knee prosthesis. Twelve specimens of the same design and manufacturing specification, were subjected to a wear test of 2 x 10(6) cycles duration using bovine serum as a lubricant. The anterior/posterior displacement and internal/external rotation inputs were based on the kinematics of the natural knee. International Standards Organization (ISO) standards were used for the flexion and axial load. The wear rates and wear scar areas were compared across all stations. The mean wear rates found were 17.6+/-5 mm3/10(6) cycles for stations 1 to 6 and 19.6+/-4 mm3/10(6) cycles for stations 7 to 12, resulting in an overall mean wear rate of 18.1+/-3 mm3/10(6) cycles. The differences between the two simulators were not significant. The average wear scar area seen on inserts from stations I to 6 was calculated at 32.4+/-1 per cent of the intended articulating surface. Similarly on stations 7 to 12 the average wear scar area was 30.7+/-3 per cent. The wear scars seen were a good physiological representation of those found from clinical explant data. This study has shown good repeatability from the simulator, both within and between the simulators.

In order to extend the lifetime of total knee replacements (TKR) in vivo, reduction of the volumetric wear rate of ultra high molecular weight polyethylene (UHMWPE) bearings remains an important goal. The volume of wear debris generated in fixed bearing total knee devices increases significantly when subjected to higher levels of internal–external rotation and anterior–posterior displacement. Six PFC Sigma fixed bearing TKR were compared with six LCS rotating platform mobile bearing knees using a physiological knee simulator with high rotation kinematic inputs. The rotating platform polyethylene inserts exhibited a mean wear rate which was one-third of that of the fixed bearing inserts despite having increased femoral contact areas and additional tibial wear surfaces. The rotating platform design decouples knee motions, by allowing unidirectional motion at the tray-insert articulation, which reduces rotation at the femoral-insert counterface. This translation of complex knee motions into more unidirectional motions results in molecular orientation of the UHMWPE and reduced volumetric wear. © 2001 Kluwer Academic Publishers

A multidirectional pin-on-plate reciprocating machine was used to compare the wear performance of UHMWPE sliding against cast cobalt chrome (CoCr) plates that were either untreated or coated with Amorphous Diamond Like Carbon (ADLC). The test conditions were based on a 1/5 scale model representative of in vivo motion at the tibial counterfaces of unconstrained mobile bearing knees. The average +/- STERR wear rates were 13.78+/-1.06 mm3/Mcycles for the ADLC counterfaces and 0.504+/-0.12 mm3/Mcycles for the control CoCr counterfaces. All of the pins run on the ADLC counterfaces exhibited the same patterns of blistering along the central axis, and severe abrasion elsewhere to the extent that all of the original machining marks were removed after just one week of testing. The average value of friction coefficient was 0.24 for the ADLC counterfaces and 0.073 for the control CoCr counterfaces. The factor of 3.5 increase was statistically significant at p < 0.05. In the tribological evaluation of ADLC coatings for tibial trays in mobile bearing knees, this study shows that this specific Physical Vapour Deposition (PVD) ADLC showed significantly poorer frictional and wear performance than uncoated surfaces which was sufficient to negate any potential benefits of improved resistance to third body damage.

Fourteen pairs of explanted low contact stress (LCS) tibial interface components: six rotating platform (RP), six meniscal (MN) and two anterior-posterior (AP) glide designs, have been analysed with particular attention paid to the condition of the tibial counterfaces. The average surface roughness, Ra, for the tibial trays ranged from 0.01 to 0.087 micron, significantly greater than the unworn control measurement of 0.008 micron. The scratch geometry analysis showed that the scratch peaks were found to be consistently of a lower aspect ratio than the scratch valleys and under 1 micron in height (average asperity height Rp = 0.52 micron, aspect ratio delta p = 0.01, average asperity depth Rv = 1.10 microns, delta v = 0.05). The largest scratches were 3-4 microns in both Rp and Rv. In vitro tests have shown that ultra-high molecular weight polyethylene (UHMWPE) wear increases in the presence of counterface scratches perpendicular to the direction of motion. In these explants, the unidirectional motion produced scratches parallel to the direction of sliding which is predicted to produce a smaller increase in UHMWPE wear. Other designs in mobile bearing knees have less constrained motion at the tibial counterface and this has been shown to accelerate wear; it may also lead to a further increase in wear in the presence of third body scratches. It may be possible in future knee designs to reduce this type of wear damage by introducing alternative materials or coatings which are more resistant to scratching and surface roughening.

Current designs of mobile bearing knees have different kinematics at the tibial counterface articulation; unidirectional represented by linear tracks and rotating platform designs, and multidirectional represented by reduced constraint designs with motion of the tibial surface in A-P and M-L directions simultaneously. One fifth scale experimental models of the tibial counterface articulation have been developed with mean contact stresses of 0.6 MPa. The unidirectional model had a linear reciprocating motion with a 10 mm stroke, the multidirectional model had a reciprocating motion with a 10 mm stroke and simultaneous rotation of +/- 7.5 degrees. Six specimens of GUR415 polyethylene were tested for each model, sliding on polished cobalt chrome counterfaces with Ra < 0.01 micron in 25% bovine serum lubricant. The mean +/- STERR wear rates were: unidirectional 0.045 +/- 0.015 mm3/million cycles and multidirectional 0.44 +/- 0.15 mm3/million cycles. Applying the scaling factor of 5, the predicted wear rates in actual knee prostheses were: unidirectional 0.23 mm3/million cycles and multidirectional 2.2 mm3/million cycles. The order of magnitude increase in wear rate was statistically significant (p = 0.05).

A composite cushion acetabular cup for a total hip replacement has been designed and developed jointly by Leeds University and DePuy International. In order to assess the long-term performance of this novel design, two sets of simulator tests of more than 4 million cycles duration have been carried out with the cushion bearings using the Leeds PA hip joint simulator with bovine serum as the lubricant. The results of these simulator tests were compared to the results from a previously reported study that used 32 mm ultrahigh molecular weight polyethylene (UHMWPE) acetabular cups. Under a physiological walking cycle simulation, with continuous cyclic motion and loading, the composite cushion cups produced negligible wear compared to a volumetric wear rate of 32 mm3 per million cycles for the conventional UHMWPE acetabular cups. This study has demonstrated for the first time the beneficial effects of fluid film lubrication in reducing wear in composite cushion acetabular cups.

Cylindrical cushion bearings have been tested under conditions of dynamic loading and variable velocity. Newtonian lubricants were used and friction was measured throughout the cycle. Stribeck assessment of each bearing was performed using the point of maximum load and velocity in the cycle. This experimental data of friction coefficient versus Sommerfeld number was compared to theoretical predictions and showed good agreement. Detailed agreement of friction throughout the cycle between theory and experiment was also obtained.

The cushion bearing concept involved the potential application of elastomeric surface layers, with a compliance similar to cartilage, in total joint replacement implants. In the present study, experiments were performed on a cushion bearing to investigate the possibility of fluid film lubrication and to compare the measured friction coefficients with theoretical predictions. A pendulum simulator apparatus was modified extensively for the experiments. The measured friction coefficients had a rising characteristic with increasing Sommerfeld parameter which suggested fluid film lubrication and a comparison of predicted film thickness to surface roughness supported this contention. However, the measured friction coefficients did not show good qualitative agreement with theory