Abstract

Abstract The wear and mechanical performance of identically designed total knee replacement (TKR) tibial bearing surfaces, which differed only in manufacturing process, were evaluated using a Stanmore KC Four Station Knee Joint Simulator. The first group utilized Co-Cr-Mo alloy femoral components with ultra-high molecular weight polyethylene (UHMWPE) tibial bearings processed by direct compression molding. The second group was identical to the first, except that the UHMWPE components were machined from a compression molded sheet. The implant alignment and testing conditions were identical for both series, with a 1 Hz standardized force-controlled walking cycle being employed for a duration of 3 million cycles. Gravimetric wear and surface roughness of the UHMWPE components were quantified every 1 million cycles. Measures of implant mechanics and kinematics were quantified every 0.1 million cycles. Results show that molded UHMWPE exhibited less wear (12 mg/million cycles) and no changes in kinematics. Moreover, the higher rate of wear (18 mg/million cycles) in the machined components was correlated with a statistically significant change in implant kinematics.

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