Polyethylene sterilization and production affects wear in total hip arthroplasties

Production and package sterilization techniques for the polyethylene used in acetabular components for total hip arthroplasties are known to affect wear. We considered three combinations of techniques: sterilization by radiation in inert gas with isostatically molded polyethylene, in inert gas and ram-extruded polyethylene, and in air with extruded polyethylene. The intent of this study was to confirm that molded polyethylene and polyethylene radiated in inert environments reduce wear rates in vivo, to determine the combination of methods with the least wear, and to determine how much variance in wear is attributable to these methods. We reviewed 150 consecutive total hip arthroplasties done in 133 patients using 28-mm cobalt-chrome femoral heads and polyethylene-lined, titanium, ring-locked acetabular components. The least wear occurred in gamma inert-molded polyethylene components. The mean volumetric wear rates were 52.12 mm3/year for gamma inert-molded, 62.32 mm3/year for gamma inert-extruded, and 66.09 mm3/year for gamma air-extruded polyethylene components. Relative risk assessment found gamma air-extruded and gamma inert-extruded polyethylene components to wear 16% and 11% more than gamma inert-molded polyethylene components, respectively. Gender, body mass index, and age accounted for the greatest amount of the explained variance in volumetric wear (57.5%, 21.6%, and 14.4, respectively), followed by angle of wear (3.4%), and sterilization and production technique (3.2%).