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Related Experiment Video

Updated: May 19, 2026

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Published on: July 24, 2018

In Vitro Wire Tension in Circular External Fixation Frames.

Isobel S Burridge1, Anthony Howard2, Paul Harwood2

  • 1Department of Trauma and Orthopaedics, Calderdale and Huddersfield NHS Foundation Trust, Huddersfield, England.

Strategies in Trauma and Limb Reconstruction
|May 18, 2026
PubMed
Summary

Achieving consistent wire tension in circular external fixation frames is crucial for fracture management. This study found that tensioner application and bolt torque significantly impact wire tension, with controlled application leading to more reliable frame performance.

Keywords:
Cyclic loadingExternal fixatorIlizarov frameLower extremitiesOrthopaedic biomechanicsOrthopaedic surgeryStabilityTension lossWire slippageWire tensioning

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Area of Science:

  • Orthopedic biomechanics
  • Biomaterials engineering

Background:

  • Circular frames are vital for fracture and osteotomy management, but their clinical performance varies due to individualization.
  • Wire tension in fine wire constructs is critical for stability but can degrade, with limited understanding of influencing factors.

Purpose of the Study:

  • To monitor wire tension in an in vitro circular frame construct.
  • To investigate clinical assembly and use factors affecting wire tension loss in external fixation.

Main Methods:

  • Utilized strain gauge instrumented wires in a symmetrical circular frame.
  • Monitored wire tension under varying assembly conditions and dynamic loading.

Main Results:

  • Variability in wire tension was linked to tensioner application and wire slippage, primarily due to bolt torque.
  • These factors could cause up to a 50% variation in achieved wire tension.
  • Despite initial slippage, wire tension remained stable under dynamic loading after three cycles.

Conclusions:

  • Consistent frame performance requires a calibrated tensioner set to high initial tension (110 kg).
  • Controlled wire clamp bolt torque (14 Nm) is essential for minimizing tension loss and ensuring predictable outcomes.