Medical Grade Ultra-high Molecular Weight Research Articles

A comprehensive review summarising the reinforcement of UHMWPE composite scaffolds as an artificial implant biomaterials

As a bearing surface, Ultra High Molecular Weight Polyethylene (UHMWPE) has been a long-standing material of choice due to its distinguished physical and mechanical properties, including lubricity, low coefficient of friction, excellent wear and impact resistance, and high resistance to corrosive chemicals. UHMWPE's oxidative breakdown in an interstitial fluid environment and processing restrictions, however, continue to be problems in biomedical applications. Research has concentrated on enhancing performance by integrating different processes, such as synthesis, manufacturing, the inclusion of organic or inorganic material, and pre- and post-processing approaches, in order to overcome obstacles. The sub-constituent composition and processing methods have an impact on the physical and mechanical properties, which in turn have an impact on how well the implant functions in the clinical setting. According to estimates, the market for medical-grade ultra-high molecular weight polyethylene is worth US$2.39 billion, and from 2015 to 2024, a compound annual growth rate (CAGR) of 5.1% is anticipated. The review manuscript highlights the recent progress on the reinforcement of UHMWPE for improvement in functional characteristics like mechanical and tribological properties and bioactivity. This study also carefully examines UHMWPE's 3D printability for a variety of biomedical applications. This article will serve as a guide for the research community to enhance their conceptual comprehension and perception of the potential of 3D printing biomedical devices and equipment built of UHMWPE.

Laser Melt Infiltration of UHMWPE into the Binary Coatings of Strontium Apatite and Colloidal Silica

Medical-grade ultrahigh molecular weight polyethylene (UHMWPE) is the material of choice for sliding surfaces in various articular joint implants owing to its excellent biocompatibility and superior physical properties, such as an exceptionally low coefficient of friction and excellent durability. However, the bioinert nature of UHMWPE limits its extended use in rapidly advancing medical fronts. In this study, bioactive surface modifications of UHMWPE were addressed using a newly developed laser-melt infiltration technique. UHMWPE was coated with binary mixtures of strontium apatite and colloidal silica particles and irradiated using a 30 W CO2 laser to reach the maximum temperature of 150 ± 5 °C. UHMWPE melts infiltrated the porous matrices of the coatings by capillary force and formed surface-selective composite materials between them. Capillary rise heights were evaluated by observing the uplift of the substrate after the selective dissolution of the coating substances and were found to be much higher than the estimated values based on the Lucas–Washburn equation. This finding suggests that the melt viscosity of UHMWPE confined within the nanopores might be significantly lower than that measured at macroscopic scales. Both strontium and silicate ions are known osteo-inductive factors, and their concentrations eluted from the binary coatings were substantially higher than those found in the single coatings.

Mechanical characteristics of medical grade UHMWPE under dynamic compression.

The mechanical properties of medical grade ultrahigh molecular weight polyethylene (UHMWPE) are critical for the safety and integrity of UHMWPE implantation. Accordingly, the mechanical features of UHMWPE are tested under repeated stress-controlled and strain-controlled compression at room temperature. Some important effect factors, such as stress rate, mean stress, stress amplitude, strain rate, mean strain, strain range and multiple load steps are further considered in detail. Results indicate that the lower stress rate causes the greater accumulated plastic strain and the accumulated plastic strain rate becomes increasingly lower with increasing number of cycles. The strain range and accumulated plastic strain rate decrease rapidly in the first stage, and then become almost steady during the second stage. Especially, the accumulated plastic strain rate per cycle for each case is less than 0.01 %/cycle after the initial 100 cycles. This means that the plastic strain accumulates very slowly and the shakedown behavior always occurs. Moreover, obvious cyclic softening and stress relaxation behaviors can be observed under cyclic strain-controlled compression during the first 50 cycles. This indicates that the accumulated plastic stain in the initial 100 cycles and the cyclic stress relaxation during the first 50 cycles should be assessed for the functionality of UHMWPE implantation.

Short-term creep and recovery behavior of medical grade ultra-high molecular weight polyethylene (UHMWPE)

Purpose: In this study, short-term tensile creep and recovery behaviors of medical gradeultra-high molecular weight polyethylene (UHMWPE) were investigated to contributedeformation behaviour of UHMWPE components in knee and hip prosthesis during daily lifeactivities of patients.Design/methodology/approach: Tensile test specimens were machined fromcompression molded UHMWPE sheets having commercial brand name: Chirulen 1020 andthey were prepared according to ASTM 527-2. The tensile creep tests were performed atconstant stress levels of 5, 9, 13, 18 and 21 MPa as long as 1 hour for each test. Then, thespecimens were allowed to recover unloaded for 1 hour. Automatic extensometer was usedto measure the deformations precisely for each test.Findings: Results show that creep rate linearly increased with increasing the stress levels.Permanent deformations were observed after recovery. Recovery of the material becamedifficult with increasing the applied load at intended time interval.Research limitations/implications: UHMWPE components used in prosthesis havebeen subjected to complex loading conditions during service life. Polymeric materials showthe viscoelastic material properties like strain rate sensitivity, relaxation, creep and recoveryat room temperature. Because of the viscoelastic material properties of the UHMWPE,it makes difficult to predict the failure of the UHMWPE components in hip and knee prosthesis.Therefore, deformation behavior of medical grade UHMWPE should be investigated in manydifferent loading conditions.Practical implications: Medical grade ultra-high molecular weight polyethylene(UHMWPE) have been used commonly in total hip replacements as acetabular cup and intotal knee replacements as tibial insert since early 1960s.

Tax policy developments, donor inflows and economic growth in Malawi

In this investigation the friction and wear performance of GUR 1020 medical grade ultra-high molecular weight polyethylene (UHMWPE) polymer under dry sliding, distilled water and egg albumen lubrication conditions were evaluated. The sliding experiments were carried out on a pin-on-disc tribometer. The contact configuration used was a polymer pin on a rotating AISI 304L stainless steel disc. Wear tests were carried out for 30 min duration at room temperature with 50, 100 and 150 N applied load values and at 0.50, 1.0 and 2.0 m/s sliding speeds condition. The results show that the coefficient of friction for GUR 1020 medical grade UHMWPE polymer is more significantly influenced by applied load and sliding speed values under dry sliding condition rather than lubricant media condition. Furthermore, the coefficient of friction and specific wear rate increases with the increase in applied load and speed values. This increase is much pronounced under dry sliding condition. Moreover, for the range of load and speed values of this study the specific wear rate using egg albumen lubricant registered lower values than that of the distilled water lubricant and the dry conditions. Finally, the specific wear rate values for GUR 1020 medical grade UHMWPE polymer under dry, water lubricant and egg albumen lubricant conditions are at the levels of 8x10-14, 1.4x10-14 and 0.5x10-14m2/N respectively. Key words: Medical Grade UHMWPE, tribology, distilled water, wear.

Studies on electron-beam irradiation and plastic deformation of medical-grade ultra-high molecular weight polyethylene

Separated and combined electron-beam irradiation and plastic deformation effects on the structures of ultra-high molecular weight polyethylene (UHMWPE) were studied. It was found that the concentration of carbonyl (ketones, esters and peresters), hydroxyl and vinyl groups increases with the growing dose of adsorbed electrons. It also tends to exhibit a slight increase in the melting point and crystallinity of the samples. A mechanical stress in the polymer was found to accelerate radiation-induced degradation. It was concluded that each of the factors studied (i.e. electron beam sterilization and plastic deformation) had a different impact on the polymer structure. The change in the sequence of action of these factors can dramatically influence the process of UHMWPE destruction. Some effects may be limited or enhanced by the action of other factors. Therefore, the resulting effects of destructive factors depend qualitatively and quantitatively on their intensity and order.

Effect of electron beam irradiation and plastic deformation on molar mass of medical grade ultra-high molecular weight polyethylene

Separated and combined electron beam irradiation (as a sterilization procedure) and plastic deformation effects on the average molar mass of ultra-high molecular weight polyethylene (UHMW-PE) were studied. It was found, that both irradiation and deformation have a different impact on the polymer structure. With the growing irradiation dose the mass-average molar of the polymer soluble fraction reduces and the amount of insoluble fraction (gel) increases. On the other hand, the plastic deformation of UHMW-PE alone may be considered as not involving any destruction of polymer macromolecules. The combined effect of these factors leads to different results in comparison to their separate action and depends on the sequence of the destructive impacts on the polymer. However independently of the sequence of both external factors their synergetic effect is observed for the degradation of UHMW-PE.

Friction and wear behavior of ultra-high molecular weight polyethylene as a function of polymer crystallinity

In this study the friction, wear and surface mechanical behavior of medical-grade ultra-high molecular weight polyethylene (UHMWPE) (GUR 1050 resin) were evaluated as a function of polymer crystallinity. Crystallinity was controlled by heating UHMWPE to a temperature above its melting point and varying the hold time and cooling rates. The degree of crystallinity of the samples was evaluated using differential scanning calorimetry (DSC). A higher degree of crystallinity in the UHMWPE resulted in lower friction force and an increase in scratch resistance at the micro- and nanoscales. On the nanoscale, the lamellar structure appeared to affect the observed wear resistance. Reciprocating-wear tests performed using a microtribometer showed that an increase in crystallinity also resulted in lower wear depth and width. Nanoindentation experiments also showed an increase in hardness values with an increase in sample crystallinity.

Effect of Crystallinity on the Friction Behavior of Ultra-high-molecular-weight-polyethylene

AbstractIn this study we evaluate the interfacial shear strength and scratch resistance of medical grade ultra-high molecular weight polyethylene (UHMWPE) (GUR 1050 resin) as a function of polymer crystallinity. Crystallinity was controlled by heating UHMWPE samples to a temperature above its melting point and varying the hold time and cooling rates. Degree of crystallinity of the samples was evaluated using differential scanning calorimetry (DSC). Quantitative nanoscale friction experiments were conducted using an atomic force microscope with commercially available Si3N4 probes under dry conditions. A higher crystallinity resulted in lower friction force and lower interfacial shear strength as well as increased scratch resistance. The trend in friction response was observed in microscale friction measurements.

Measurements of free radicals over a period of 4.5 years in gamma-irradiated ultra-high molecular weight polyethylene

Gamma irradiation-induced free radicals have been investigated for 4.5 years in medical grade ultra-high molecular weight polyethylene resins, GUR 4120, GUR 4150 and Himont 1900, at room temperature (23 °C) in absence (vacuum) or presence of oxygen (air), and at 75 °C in vacuum. In vacuum, the primary radicals (predominantly allyl) decayed following Y= Y R+ ae− bt and, in 30 days at 75 °C or 100 days at 23 °C, their concentration was reduced from ∼10 17 radical/g (initial) to a minimum Y R∼10 15 radical/g and remained at this level as long as the samples were kept in vacuum. When the samples were exposed to air, at any time during this study, these residual radicals were found to decay to a very stable, polyenyle-type terminal radical.

J-integral fracture toughness and tearing modulus measurement of radiation cross-linked UHMWPE

Radiation and chemical cross-linking of medical grade ultrahigh molecular weight polyethylene (UHMWPE) has recently been utilized in an effort to improve wear performance of total joint replacement components. However, reductions in mechanical properties with cross-linking are cause for concern regarding the use of cross-linked UHMWPE for high-stress applications such as in total knee replacement prostheses. In this study, the fracture behavior of radiation cross-linked UHMWPE was compared to that of uncross-linked UHMWPE. The Rice and Sorensen model that utilizes mechanical parameters obtained from uniaxial tensile and compact tension tests was used to calculate the steady state J-integral fracture toughness, J ss, for radiation cross-linked UHMWPE. J ss decreased monotonically with increase in radiation dose. UHMWPE exhibited tough, ductile tearing behavior with stable crack growth when it was cross-linked using a gamma radiation dose of 0–50 kGy. However, in cross-linked UHMWPE irradiated to a dose of 100 and 200 kGy, unstable fracture occurred spontaneously upon attaining the initial crack driving force, J 1c. This indicates that a high degree of cross-linking is less desirable for high-stress applications in orthopaedic implants. However, a substantial increase in J 1c, even at a low degree of cross-linking, suggests that a low degree of cross-linking may be beneficial for resistance to delamination and catastrophic failure, both of which require an initiation step for the fracture to propagate in the material. This mechanical test should, however, be considered along with fatigue tests and joint simulator testing before determination of an appropriate amount of cross-linking for total joint replacement prostheses that experience high stresses.

Effects of Counterface Roughness and Conformity on the Tribological Performance of Crosslinked and Non-crosslinked Medical-Grade Ultra-High Molecular Weight Polyethylene

AbstractThe tribological behavior of crosslinked ultra-high molecular weight polyethylene (UHMWPE) was compared to that of non-crosslinked UHMWPE, used as control sample. A reciprocating pin-on-disk tribometer was used to determine the effects of countersurface roughness and conformity on wear mechanisms occurring during the initial stage of sliding. Pin samples of two different radii of curvature were slid against medical-grade Co-Cr alloy disks with surface roughness ranging from 0.005 to 0.04 μm in a lubricant of bovine serum. Normal loads were chosen to provide physiological contact stresses. The focus of this study was on the dependence of early wear mechanisms on surface roughness and conformity. Although a correlation between coefficient of friction data and dominant wear mechanisms was not observed, different wear mechanisms were found between control and crosslinked UHMWPE. The results of this study provide insight into the differences of the initial wear behavior of noncrosslinked and crosslinked UHMWPE used in total joint replacements.

Study of fatigue resistance of chemical and radiation crosslinked medical grade ultrahigh molecular weight polyethylene

The aim of this work is to understand the role of chemical and radiation induced crosslinking on the fatigue crack propagation resistance of medical grade ultrahigh molecular weight polyethylene (UHMWPE). In recent years, the need to improve the tribological performance of UHMWPE used in total joint replacements has resulted in the widespread utilization of crosslinking as a method to improve wear resistance. Although crosslinking has been shown to drastically improve the wear resistance of the polymer, the potential trade-off in fatigue properties has yet to be addressed. Fatigue crack propagation resistance is a concern in tibial inserts where large cyclic stresses are sufficient to drive the growth of subsurface cracks that potentially contribute to delamination wear mechanisms. For clinical relevance, the combined effects of sterilization and aging are examined in two commercially available crosslinked resins. Nonsterile and unaged resins serve as a control. To evaluate the effect of crosslinking, a comparison is made to uncrosslinked resins. Scanning electron microscopy is used to provide an understanding of fatigue fracture mechanisms in the crosslinked polymers. The results of this study show that the current level of crosslinking used in orthopedic resins for enhanced wear resistance is not beneficial for fatigue crack propagation resistance. © 1999 John Wiley & Sons, Inc. J Biomed Mater Res, 46, 573–581, 1999.

Diamond-like carbon coatings for orthopaedic applications: an evaluation of tribological performance.

A detailed investigation of the tribological behaviour of vacuum arc diamond-like carbon coated Ti-6Al-4V against a medical grade ultra-high molecular weight polyethylene is conducted in this work in order to investigate the potential use of diamond-like carbon coatings for orthopaedic appplications. Lubricated and non-lubricated wear experiments are performed using a standard pin-on-disc wear tester. The coefficient of friction is monitored continuously during testing and wear rate calculations are performed using surface profilometry measurements of worn disc surfaces. Sliding wear tests show the existence of two distinct friction and wear regimes distinguished by physically different mechanisms. In the first stages of wear, adhesion and abrasion are the dominant mechanisms of wear while fatigue processes are activated later in the tests. The effects of diamond-like carbon coating structure, surface roughness and lubrication on tribological behaviour are presented. Optimal process-structure-property design for vacuum arc plasma deposition is utilized in order to obtain strong adhesion to the titanium alloy substrate. Diamond-like carbon coatings significantly improve the friction and wear performance of the orthopaedic bearing pair and show exceptional promise for biomedical applications.

The effects of hydrogen peroxide and sterilization on the structure of ultra high molecular weight polyethylene

The effects of hydrogen peroxide and sterilization on the structure and morphology of medical-grade ultra high molecular weight polyethylene (UHMWPE) were studied. Microstructural changes were induced via gamma irradiation sterilization and were accelerated by aging in hydrogen peroxide. Differential scanning calorimetry, density gradient column, transmission electron microscopy and small-angle X-ray scattering were used to characterize the structure. Upon oxidation, a decrease in melting temperature, an increase in heat of fusion, an increase in density, a tortuosity in lamellae, and a tendency to microcrack were observed. Based on the results, a mechanism for the oxidation of UHMWPE is proposed in which oxygen is incorporated into the amorphous phase of the polymer, leading to the development of strains and the breaking of tie molecules in the polymer, which result in the microcracking and embrittlement of the material.

Plasma Surface Modification of Medical-Grade Ultra-High Molecular Weight Polyethylene for Improved Tribological Properties

AbstractUltra-high molecular weight polyethylene (UHMWPE) is the principal material used to replace damaged cartilage in total joint replacement surgeries. This publication presents preliminary results from a new class of surface treatments to modify the surface chemistry and microstructure of UHMWPE under controlled processing conditions. Radio frequency plasmas were used to lightly crosslink the subsurface of UHMWPE and to modify the surface chemical state through the attachment of low-surface-energy fluorocarbon groups. A pin-on-disk apparatus was used to slide CoCrWNi pins with spherical tips on polished disks of plasma- treated and untreated UHMWPE immersed in a bath of preserved bovine serum. The wear resistance and surface chemical composition of tested specimens were characterized by surface profilometry and X-ray photoelectron spectroscopy (XPS), respectively. Changes in the surface hydrophobicity due to plasma treatment were evaluated using contact angle measurements. The prospect of surface plasma treatment in orthopedic applications is elucidated in the context of the obtained friction, wear, distilled water contact angle, and XPS results.

The influence of sterilization technique and ageing on the structure and morphology of medical-grade ultrahigh molecular weight polyethylene.

The effects of four sterilization treatments (gamma radiation in nitrogen, electron-beam radiation, ethylene oxide gas, and no sterilization) on the structure and morphology of ultrahigh molecular weight polyethylene (UHMWPE) were monitored as a function of ageing time in air for a period of 1.5 y. Characterization techniques employed include differential scanning calorimetry, density gradient column, transmission electron microscopy, and small-angle X-ray scattering. Ethylene oxide gas does not affect the structure of the polymer. Both forms of radiation lead to measurable alterations of the material's structure, including an increase in crystallinity, an increase in density, and the enhancement of lamellae crystalline stacking. Most changes in structure occur in the first few months with little differences observed upon subsequent ageing in air. The sharpness of the crystalline-amorphous boundaries decreases with time for irradiated UHMWPE and is believed to be linked to the oxidation of the polymer.

Effects of batch to batch variations and test methodology on degree of crystallinity and melting temperature of UHMW-PE as measured by differential scanning calorimetry

The thermal and structural analysis of a total 22 batches from three medical grade ultrahigh molecular weight polyethylene (UHMW-PE) resins was determined using the DSC method. Batch to batch variations of approximately 5% were obtained for the melting temperature and the degree of crystallinity. The variations correlated both to the changes caused by gamma-irradiation sterilization and subsequent aging, and to the differences in DSC results obtained from various laboratories on materials believed to exhibit essentially similar clinical performances. Varying the sample weight from 4.4 to 27.1 mg resulted in a significant relative increase of 5% in the degree of crystallinity. The study shows that the standard double melting/recrystallisation procedure for DSC evaluation produces variations in the melting behaviors of approximately the same magnitude as those indicated by batch lot or sterilization/aging.