Staple leg profile influence on pullout strength: a biomechanical study

Bone staples have widespread applicability in orthopaedic surgery. Their use, however, is limited by inconsistent quality of fixation. Prior studies have shown potential for improvement in the reliability of staple fixation through a change in the design of the staple legs. To identify a superior leg cross section profile, pullout strength of 5 different newly designed staple leg cross sections were evaluated in fresh frozen human cadaveric bones before and after toggle loading. The tests were repeated in a synthetic bone model with variable but consistent densities. The curvilinear square profile had the highest pullout strength in both the cadaveric and synthetic bone, followed in descending order by square, circular, and triangular profiles. Controlling for density, the pullout strength of the curvilinear square profile was 8% higher than the square profile and 34% higher than the circular profile. The triangular profiles had the least resistance to pullout force before and after cyclic loading. The curvilinear square may be the best profile for the cross section of the staple leg for maximum pullout strength and may expand the clinical use of staples in bone fixation.