High speed fracture fixation: assessing resulting fixation stability and fastener withdrawal strength.

A new method of bone fracture fixation has been developed in which fixation darts (small diameter nails/pins) are driven across a fracture site at high velocity with a pneumatically powered gun. When fixation darts are inserted oblique to one another, kinematic constraints prevent fragment motion and allow bone healing to progress. The primary aim of this study is to determine if fixation darts can provide reasonable fixation stability compared to bone screws, which were used as a benchmark since they represent a simple, yet well-established, surgical technique. The first objective was to evaluate macro-level stability using different numbers of darts inserted parallel and oblique to each other; experimental comparisons were undertaken in a bone analog model. Experimental results showed fixation darts could not be substituted for screws on a one-to-one basis, but that a plurality of fixation darts provided comparable fixation to two bone screws while allowing for faster insertion and damaging less bone. A second objective was to evaluate micro-level stability; a finite element model was created in order to provide a detailed look at the stress state surrounding the fixation darts and the evolution of the fracture gap. Even with relatively weak fixation dart configurations, the fracture gap was maintained below physiological thresholds for bone healing. Most failures of the fixed fractures were attributed to fixation dart pullout from the cancellous structure. The final objective of the study was to characterize this mode of failure with separate fixation dart and screw pullout tests conducted in Sawbones® cancellous foam and fresh porcine cancellous bone. The results showed that the cancellous foam was an acceptable substitute for real bone and provided a conservative estimate of the fixation darts' performance relative to bone screws. A final comparison between experimental and numerically predicted pullout strengths provided confirmation that the model and experiments were consistent.

High speed insertion of bone fracture fixation pins: a finite element penetration model with experimental comparisons.

A new method of bone fracture fixation is considered in which small pins/darts are dynamically inserted into bone to prevent translation and rotation at the fracture site. An ABAQUS model was developed to analyze dart penetration in cortical and cancellous bone for varying dart diameter, material, and velocity, and cortical thickness. The method is advocated for bioresorbable darts, so polylactide (PLA) and magnesium are the materials examined in this study. Numerical results showed that magnesium darts can achieve full penetration in bone while suffering little damage. The PLA darts penetrated thin bone well, but substantial deformation was seen as the cortical thickness increased, especially for small diameter darts. As partial validation, prototype PLA fixation darts were fired into cadaveric bone with a custom nailer. As in the model, the PLA darts could penetrate thin cortices but saw gross deformation when impacted against thicker bone.

Use of a Novel Polymer-Coated Steel as an Alternative to Traditional Can Manufacturing in the Food Industry.

Metal containers (both food and beverage cans) are made from huge steel or aluminum coils that are transformed into two- or three-piece products. During the manufacturing process, the metal is sprayed on both sides and the aerosol acts as insulation, but unfortunately produces volatile organic compounds (VOCs). The present work presents a different way to manufacture these containers using a novel prelaminated two-layer polymer steel. It was experimentally possible to verify that the material survives all the involved manufacturing processes. Thus tests were carried out in an ironing simulator to measure roughness, friction coefficient and surface quality. In addition, two theoretical ironing models were developed: upper bound model and artificial neural network. These models are useful for packaging designers and manufacturers.