Characterization of commercial rigid polyurethane foams used as bone analogs for implant testing

Mechanical properties and microstructure characterization of a series of graded commercial rigid polyurethane foams commonly used to mimic trabecular bone in testing orthopaedic devices is reported. Compressive testing conducted according to ASTM standard F1839-08, which requires large specimens (50.8 mm x 50.8 mm x 25.4 mm blocks) gave elastic modulus and compressive strength values ranging from 115 to 794 MPa and 4.7 to 24.7 MPa, respectively, for foams having densities of 0.240-0.641 g/cm(3). All these results were within the requirements of the specification for the corresponding grades. Compression testing using smaller specimens (7.5 mm diameter x 15 mm) typical of testing bone, gave results in good agreement with those obtained in the standard tests. Microstructural measurements showed the average pore size ranged from 125 to 234 microm for densities ranging from 0.641 to 0.159 g/cm(3), respectively. The relative modulus as a function of relative density of the foams fit well to the model of Gibson and Ashby. Cyclic testing revealed hysteresis in the lower density foams with a loading modulus statistically equivalent to that measured in monotonic testing. Shore DO durometry (hardness) measurements show good correlations to elastic modulus and compressive strength. The results suggest additional parameters to consider for the evaluation of polyurethane foams for bone analog applications.