Effect of fabrication method and resin type on performance of tibial bearings

Polyethylene has been used successfully for more than 30 years as an orthopedic bearing material. During this time, several polyethylene resins and fabrication methods have been used to produce bearings. Some bearings fail prematurely due to fatigue, which has been linked to oxidation and degradation of mechanical properties resulting from gamma sterilization in air. Fabrication method and/or resin have been hypothesized to govern whether oxidative degradation occurs in gamma-sterilized bearings. This study evaluates the effect of fabrication (machining/direct compression molding) and resin type on oxidation and the resulting mechanical properties for a large series of never-implanted bearings. While many molded bearings studied exhibit lower oxidation than machined bearings, fabrication method is not a significant predictor of oxidation. Resin type and shelf-age are found to be significant predictors of oxidation. Bearings fabricated from Himont 1900 exhibit lower oxidation than those from GUR 415/412 at comparable times after gamma in air. However, Himont 1900 bearings lose strength and elongation at lower oxidation levels than GUR 415/412 bearings. But since Himont 1900 oxidizes more slowly, Himont 1900 bearings retain mechanical properties for longer shelf times than comparable GUR 415/412 bearings. These effects are seen in retrievals as well.