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An Adaptable Computed Tomography-Derived Three-Dimensional-Printed Alignment Fixture Minimizes Errors in Radius

Jordan V Inacio1, Danielle M Cristino2, Michael W Hast2

  • 1Department of Mechanical Engineering & Mechanics, Packard Laboratory, Lehigh University, 19 Memorial Drive West, Bethlehem, PA 18015.

Journal of Biomechanical Engineering
|June 11, 2021
PubMed
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A new 3D-printed fixture precisely aligns long bones for biomechanical testing, reducing errors. Torsion tests are reliable, but axial tests require careful alignment to avoid significant inaccuracies.

Area of Science:

  • Biomechanics
  • Orthopedic Research
  • Medical Device Design

Background:

  • Biomechanical testing of long bones is crucial for understanding bone health and designing orthopedic implants.
  • Specimen malalignment during mechanical testing introduces significant errors and uncertainty.
  • Existing methods for aligning bone specimens are often imprecise, limiting test accuracy.

Purpose of the Study:

  • To develop and validate a novel, customizable fixture for accurate long bone specimen alignment in biomechanical testing.
  • To quantify the impact of malalignment on torsional and axial mechanical properties of long bones.
  • To establish guidelines for optimal specimen preparation in biomechanical studies.

Main Methods:

  • Designed and 3D-printed a customizable alignment and potting fixture based on specimen-specific CT scans.

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  • Performed benchtop torsional biomechanical tests and compared results with finite element models.
  • Utilized computational models to simulate malalignment effects on torsion and axial compression tests.

    • Main Results:

    • The novel fixture demonstrated high accuracy, with benchtop torsional test results strongly correlating with finite element models (R2 = 0.95).
    • Torsion testing showed robustness to alignment errors, with <8% error across malalignment scenarios.
    • Axial compression testing was highly sensitive to malalignment, with errors up to 170%.

    Conclusions:

    • The custom-designed fixture effectively ensures precise specimen alignment for biomechanical testing.
    • Torsion testing is a reliable method for assessing bone mechanical properties, less affected by alignment errors.
    • Accurate specimen alignment is critical for sensitive biomechanical tests like axial compression, especially for applications in orthopedic implant design.