Measuring Orthopedic Plate Strain to Track Bone Healing Using a Fluidic Sensor Read via Plain Radiography

We describe a fluidic X-ray visualized strain indicator under applied load (X-VISUAL) to quantify orthopedic plate strain and inform rehabilitative care.

The sensor comprises a polymeric device with a fluidic reservoir filled with a radio-dense fluid (cesium acetate) and an adjoining capillary wherein the liquid level is measured. A stainless-steel lever attaches to the plate and presses upon the acrylic bulb with a displacement proportional to plate bending strain. The sensor was attached to a plate in a Sawbones composite tibia mimic and a human cadaveric tibia. An osteotomy model (5 mm gap) was used to simulate an unstable fracture, and allograft repair to simulate a stiffer healed fracture. The cadaveric and Sawbones tibia were cyclically loaded five times (0-400 N) using a mechanical test stand, and fluid displacement was measured from plain radiographs.

The sensor displayed reversible and repeatable behavior with a slope of 0.096 mm/kg and fluid level noise of 50-80 micrometer (equivalent to 5-10 N). The allograft-repaired composite fracture was 13 times stiffer than the unstable fracture.

An analysis of prior external fracture fixation studies and fatigue curves for internal plates indicates that the threshold for safe weight bearing should be 1/5^th-1/10^th of the initial bending for an unstable fracture. The precision of our device (<2% body weight) should thus be sufficient to track fracture healing from unstable through safe weight bearing.

The X-VISUAL fluidic sensor enables orthopedic plate strain quantification to monitor facture healing via X-ray imaging.