Cutting errors in preparation of femoral components in total knee arthroplasty

Cutting errors that occur during preparation of the femoral component can deter fixation in cementless total knee arthroplasty. This study evaluated the causes of femoral cutting errors and identified methods to minimize these errors. The cutting error caused by toggle of the saw blade in the guide-slot was measured with wood blocks, a cutting guide with 1.5 mm guide slots, and four kinds of saw blades (narrow and wide blades with thicknesses of standard 1.2 mm and thicker 1.4 mm). Another cause of cutting errors, relative motions between the cutting guide and distal femur due to vibration of the saw blade during bone cuts, was measured with preserved cadaver femurs. Various combined fixation methods with intramedullary rod, pins, and clamps were compared. The maximum cutting error caused by toggle of the saw blade in the slot was significantly reduced by using the thicker 1.4 mm saw blade, but the differences between wide and narrow blades in each thickness were not significant. Mean maximum cutting error at the cutting depth of 5 cm with 1.2 mm thick saw blades was 802 microns, and with 1.4 mm thick saw blades it was 488 microns. In the measurement of relative motion, fixation with only pins or clamps did not provide tight fixation and had deflections from 200 microns to more than 1 mm. The best fixation was obtained by combining fixation methods of intramedullary rod and pins or clamps. This resulted in total movement of less than 100 microns. The results of this study indicate that both toggle of the saw blade in the slot and motion of the cutting guide can cause major cutting errors. Cutting error can be minimized by using thicker saw blades and by fixing the cutting guide to the distal femur with combined fixation methods of a central rod and peripheral pins or clamps.