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Performance test of different 3.5 mm drill bits and consequences for orthopaedic surgery
Hans Clement1, Christoph Zopf2, Markus Brandner3
1Department for Traumatology, Medical University of Graz, Auenbruggerplatz 5, 8036, Graz, Austria.
Archives of Orthopaedic and Trauma Surgery
|September 27, 2015
Summary
Orthopaedic drill bit durability varies. Zirconium-oxide bits show superior wear resistance (>100 holes), while coated HSS bits offer a cost-effective alternative to AISI 440A bits, which should be replaced after 20 holes.
Area of Science:
- Orthopaedic surgery
- Biomaterials science
- Surgical instrumentation
Background:
- Drilling bone is a common orthopaedic and trauma surgery procedure.
- Current guidelines lack recommendations on optimal drill bit selection and replacement intervals.
- Understanding drill bit wear is crucial for surgical efficiency and patient safety.
Purpose of the Study:
- To evaluate the abrasive wear resistance of different drill bits and coatings used in orthopaedic bone drilling.
- To determine the optimal replacement point for commonly used drill bits based on wear analysis.
- To compare the performance of various drill bit materials and coatings under simulated surgical conditions.
Main Methods:
- Surgeon drilling patterns (spindle speed, feeding force) were recorded.
- Four drill bit types (AISI 440A, HSS, AISI 440B, Zirconium-oxide) and two coatings (DLC, Ti-N) were tested.
- Abrasive wear was analyzed using magnification, scanning electron microscopy (SEM), and a friction stir welding machine (FSWM).
Main Results:
- The average feeding force applied by surgeons was 45 ± 15.6 N.
- High-speed steel (HSS) bits remained usable after 51 holes; coated HSS showed minimal wear.
- Zirconium-oxide (ZrO2) dental drill bits demonstrated excellent durability with no significant wear after over 100 holes.
- Coated AISI 440A bits exhibited cutting edge breakouts after 20 holes, necessitating replacement.
Conclusions:
- AISI 440A drill bits should be replaced after 20 hand-driven holes if visual inspection (20-30× magnification) reveals damage.
- Coated high-speed steel (HSS) drill bits present a durable and cost-effective alternative for orthopaedic bone drilling.
- Zirconium-oxide drill bits offer superior longevity and performance for extensive bone drilling applications.
