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Related Experiment Video

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How do CAD models compare with reverse engineered manufactured components for use in wear analysis?

Matthew G Teeter1, Douglas D R Naudie, Robert B Bourne

  • 1Imaging Research Laboratories, Robarts Research Institute, 100 Perth Drive, London, ON, N6A 5K8, Canada. mteeter@imaging.robarts.ca

Clinical Orthopaedics and Related Research
|October 22, 2011
PubMed
Summary

Manufacturing variations in tibial inserts can lead to inaccurate polyethylene wear measurements. Using scanned inserts as a reference may provide a more accurate pre-implantation geometry than CAD models for wear analysis.

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Area of Science:

  • Biomaterials science
  • Orthopedic implant analysis
  • Wear quantification

Background:

  • Accurate polyethylene wear quantification in retrieved arthroplasty components requires precise estimation of original geometry.
  • Computer-aided design (CAD) models or pristine inserts serve as reference geometries.
  • Manufacturing tolerances can introduce discrepancies between CAD models and actual inserts.

Purpose of the Study:

  • To quantify deviations between CAD models and newly manufactured tibial inserts.
  • To compare these deviations with those obtained using a never-implanted insert as a reference geometry.

Main Methods:

  • Five cruciate-retaining (CR) and five posterior-stabilizing (PS) tibial inserts and their CAD models were obtained.
  • Inserts were scanned and reconstructed using microcomputed tomography (micro-CT).
  • Volume and surface geometry differences were measured against individual inserts, CAD models, and an averaged reference geometry.

Main Results:

  • Micro-CT volumes were on average 0.4% smaller than CAD model volumes.
  • Mean surface geometry deviation was 25.7 μm (CR) and 36.8 μm (PS) smaller compared to CAD models.
  • Mean deviation from an averaged reference geometry was 1.4 μm larger (CR) and 0.4 μm smaller (PS).

Conclusions:

  • Significant deviations exist between manufactured tibial inserts and CAD models, potentially causing errors in wear measurements.
  • Scanned inserts may offer a more accurate representation of pre-implantation geometry than CAD models.
  • These geometric inaccuracies could lead to wear estimation errors equivalent to one year of wear.