Are PEEK-on-Ceramic Bearings an Option for Total Disc Arthroplasty? An In Vitro Tribology Study.

BACKGROUND: Most contemporary total disc replacements (TDRs) use conventional orthopaedic bearing couples such as ultrahigh-molecular-weight polyethylene (polyethylene) and cobalt-chromium (CoCr). Cervical total disc replacements incorporating polyetheretherketone (PEEK) bearings (specifically PEEK-on-PEEK bearings) have been previously investigated, but little is known about PEEK-on-ceramic bearings for TDR. QUESTIONS/PURPOSES: (1) What is the tribologic behavior of a PEEK-on-ceramic bearing for cervical TDR under idealized, clean wear test conditions? (2) How does the PEEK-on-ceramic design perform under impingement conditions? (3) How is the PEEK-on-ceramic bearing affected by abrasive wear? (4) Is the particle morphology from PEEK-on-ceramic bearings for TDRs affected by adverse wear scenarios? METHODS: PEEK-on-ceramic cervical TDR bearings were subjected to a 10 million cycle ideal wear test based on ASTM F2423 and ISO 181912-1 using a six-station spine wear simulator (MTS, Eden Prairie, MN, USA) with 5 g/L bovine serum concentration at 23° ± 2° C (ambient temperature). Validated 1 million cycle impingement and 5 million cycle abrasive tests were conducted on the PEEK-on-ceramic bearings based, in part, on retrieval analysis of a comparable bearing design as well as finite element analyses. The ceramic-on-PEEK couple was characterized for damage modes, mass and volume loss, and penetration and the lubricant was subjected to particle analysis. The resulting mass wear rate, volumetric wear rate, based on material density, and particle analysis were compared with clinically available cervical disc bearing couples. RESULTS: The three modes of wear (idealized, impingement, and abrasive) resulted in mean mass wear rates of 0.9 ± 0.2 mg/MC, 1.9 ± 0.5 mg/MC, and 2.8 ± 0.6 mg/MC, respectively. The mass wear rates were converted to volumetric wear rates using density and found to be 0.7 ± 0.1 mm3/MC, 1.5 ± 0.4 mm3/MC, and 2.1 ± 0.5 mm3/MC, respectively. During each test, the PEEK endplates were the primary sources of wear and demonstrated an abrasive wear mechanism. Under idealized and impingement conditions, the ceramic core also demonstrated slight polishing of the articulating surface but the change in mass was unmeasurable. During abrasive testing, the titanium transfer on the core was shown to polish over 5 MC of testing. In all cases and consistent with previous studies of other PEEK bearing couples, the particle size was primarily < 2 µm and morphology was smooth and spheroidal. CONCLUSIONS: Overall, the idealized PEEK-on-ceramic wear rate (0.7 ± 0.1 mm3/MC) appears comparable to the published wear rates for other polymer-on-hard bearing couples (0.3-6.7 mm3/MC) and within the range of 0.2 to 1.9 mm3/MC reported for PEEK-on-PEEK cervical disc designs. The particles, based on size and morphology, also suggest the wear mechanism is comparable between the PEEK-on-ceramic couple and other polymer-on-ceramic orthopaedic couples. CLINICAL RELEVANCE: The PEEK-on-ceramic bearing considered in this study is a novel bearing couple for use in total disc arthroplasty devices and will require clinical evaluation to fully assess the bearing couple and total disc design. However, the wear rates under idealized and adverse conditions, and particle size and morphology, suggest that PEEK-on-ceramic bearings may be a reasonable alternative to polyethylene-on-CoCr and metal-on-metal bearings currently used in cervical TDRs.

The Latest Lessons Learned from Retrieval Analyses of Ultra-High Molecular Weight Polyethylene, Metal-on-Metal, and Alternative Bearing Total Disc Replacements.

Knowledge regarding the in vivo performance and periposthetic tissue response of cervical and lumbar total disc replacements (TDRs) continues to expand. This review addresses the following four main questions: 1) What are the latest lessons learned from polyethylene in large joints and how are they relevant to current TDRs? 2) What are the latest lessons learned regarding adverse local tissue reactions from metal-on-metal, CoCr bearings in large joints and how are they relevant to current TDRs? 3) What advancements have been made in understanding the in vivo performance of alternative biomaterials, such as stainless steel and polycarbonate urethane, for TDRs in the past five years? 4) How has retrieval analysis of all these various artificial disc bearing technologies advanced the state of the art in preclinical testing of TDRs? The study of explanted artificial discs and their associated tissues can help inform bearing selection as well as the design of future generations of disc arthroplasty. Analyzing retrieved artificial discs is also essential for validating preclinical test methods.

Comparison of in vivo and simulator-retrieved metal-on-metal cervical disc replacements.

BACKGROUND: Cervical disc arthroplasty is regarded as a promising treatment for myelopathy and radiculopathy as an alternative to cervical spine fusion. On the basis of 2-year clinical data for the PRESTIGE(®) Cervical Disc (Medtronic, Memphis, Tennessee), the Food and Drug Administration recommended conditional approval in September 2006 and final approval in July 2007; however, relatively little is known about its wear and damage modes in vivo. The main objective was to analyze the tribological findings of the PRESTIGE(®) Cervical Disc. This study characterized the in vivo wear patterns of retrieved cervical discs and tested the hypothesis that the total disc replacements exhibited similar surface morphology and wear patterns in vitro as in vivo. METHODS: Ten explanted total disc replacements (PRESTIGE(®), PRESTIGE(®) I, and PRESTIGE(®) II) from 10 patients retrieved after a mean of 1.8 years (range, 0.3-4.1 years) were analyzed. Wear testing included coupled lateral bending ( ±4.7°) and axial rotation ( ±3.8°) with a 49 N axial load for 5 million cycles followed by 10 million cycles of flexion-extension ( ±9.7°) with 148 N. Implant surfaces were characterized by the use of white-light interferometry, scanning electron microscopy, and energy dispersive spectroscopy. RESULTS: The explants generally exhibited a slightly discolored, elliptic wear region of varying dimension centered in the bearing center, with the long axis oriented in the medial-lateral direction. Abrasive wear was the dominant in vivo wear mechanism, with microscopic scratches generally oriented in the medial-lateral direction. Wear testing resulted in severe abrasive wear in a curvilinear fashion oriented primarily in the medial-lateral direction. All retrievals showed evidence of an abrasive wear mechanism. CONCLUSIONS: This study documented important similarity between the wear mechanisms of components tested in vitro and explanted PRESTIGE(®) Cervical Discs; however, the severity of wear was much greater during the in vitro test compared with the retrievals.

What is the correlation of in vivo wear and damage patterns with in vitro TDR motion response?

STUDY DESIGN: This study combined the evaluation of retrieved total disc replacements (TDRs) with a biomechanical study using human lumbar spines. Thirty-eight CHARITE TDRs were retrieved from 32 patients after 7.3 years average implantation. All implants were removed because of intractable back pain and/or facet degeneration. In parallel, 20 new implants were evaluated at L4-L5 and L5-S1 in an in vitro lumbar spine model. OBJECTIVE: The purpose of this study was to correlate wear and damage patterns in retrieved TDRs with motion patterns observed in an in vitro lumbar spine model. We also sought to determine whether one-sided wear and motion patterns were associated with greater in vivo wear. SUMMARY OF BACKGROUND DATA: The comparison of polyethylene wear in TDRs after long-term implantation to those tested using an in vitro model had not yet been investigated. METHODS: The wear patterns of each retrieved PE core was analyzed at the rim and dome. Thirty-five cores were further analyzed using MicroCT to determine the penetration symmetry. For the in vitro study the implants were tested under physiologic loads using a validated cadaveric model. Motion patterns of the in vitro-tested implants were tracked using sequential video-fluoroscopy. RESULTS: Fifteen of 35 retrieved cores (43%) displayed one-sided wear patterns. Significant correlations were observed between implantation time and penetration and penetration rate. In the in vitro study, there was evidence of motion at both articulations, motion at both articulation but predominantly at the top articulation, and solelyat the top articulation. Core entrapment and pinching was observed and associated with visual evidence of core bending or deformation. CONCLUSION: This is the first study to directly compare the long-term PE wear and damage mechanisms in TDR retrievals with the motion patterns generated by a validated in vitro cadaveric testing model. The retrievals exhibited wear patterns consistent with the in vitro testing.

Polyethylene wear and rim fracture in total disc arthroplasty.

BACKGROUND CONTEXT: Polyethylene (PE) has been used in total disc replacements (TDRs) in Europe since the 1980s. However, the extent of surface damage of PE, including rim fracture and wear, after long-term implantation remains poorly understood. PURPOSE: The purpose of this study was to evaluate the magnitude and rate of PE wear and surface damage in TDRs. STUDY DESIGN: TDR components were retrieved from patients undergoing revision TDR surgery and conversion to fusion. PATIENT SAMPLE: Twenty-one implants (SB Charité III; DePuy Spine, Raynham, MA) were analyzed from 18 patients (12 female, 6 male) undergoing TDR revision surgery. The components were implanted between 1.8 and 16.0 years (average: 7.8 years) at L2-L3 (n=1), L3-L4 (n=1), L4-L5 (n=11), and L5-S1 (n=8). They were removed due to pain (in all cases) and were associated with subsidence (n=6), anterior migration (n=2), core dislocation (n=2), lateral subluxation (n=1), wear with wire marker fracture (n=1), end plate loosening (n=2), and osteolysis (n=1). OUTCOME MEASURES: Clinical information was collected from medical records and radiographs. Retrieval analysis included dimensional measurements and assessment of the extent and severity of PE surface damage mechanisms. METHODS: MicroCT scanning was used to identify the presence of internal cracks in the PE core and to scan the geometry of the retrievals. Light microscopy, coupled with white light interferometry, was used to evaluate the surface damage mechanisms at the dome and rim. RESULTS: The dominant wear mechanism was adhesive/abrasive wear at both the dome and rim. End plate penetration (dome wear) ranged from 0.1 to 0.9 mm (average: 0.3 mm), and was correlated with implantation time (Spearman's rho=0.48, p=.03). There was also evidence of macroscopic rim damage, including radial and transverse cracking, fracture, plastic deformation, and third-body damage. End plate penetration measured at the rims ranged from 0.02 to 0.8 mm (average: 0.3 mm). Cracks in the core were oriented transversely in 11 of 21 implants (52%), and radially around the rim in 11 of 21 implants (52%). Radiographic wire marker fracture, observed in 9 of 21 implants (43%), was always associated with deformation, cracking, or fracture of the PE rim. In two cases, a fractured wire marker became lodged in the articulating surface between the PE and the metallic end plate. CONCLUSIONS: This is the first study to quantitatively analyze the long-term PE damage mechanisms in contemporary TDRs. The TDRs displayed surface damage observed previously in both hip and knee replacements. Because of the evidence of increasing wear with implantation time, along with the demonstrated potential for osteolysis in the spine, regular long-term follow-up for patients undergoing TDRs is warranted.