An increasingly used treatment for end-stage ankle osteoarthritis is total ankle replacement (TAR). However, implant loosening and subsidence are commonly reported complications, leading to relatively high TAR failure rates. Malalignment of the TAR has often been postulated as the main reason for the high incidence of these complications. It remains unclear to what extent malalignment of the TAR affects the stresses at the bone-implant interface. Therefore, this study aims to elucidate the effect of TAR malalignment on the contact stresses on the bone-implant interface, thereby gaining more understanding of the potential role of malalignment in TAR failure.FE models of the neutrally aligned as well as malaligned CCI Evolution TAR implant (Van Straten Medical) were developed. Separate models were developed for the tibial and talar segment, with the TAR components in neutral alignment and 5° and 10° varus, valgus, anterior and posterior malalignment, resulting in a total of 9 differently aligned TAR models. Loading conditions of the terminal stance phase of the gait cycle, when the force on the ankle joint is highest (5.2x body weight), were applied. Peak and mean contact pressure and shear stress at the bone-implant interface were analyzed. Also, stress distributions on the bone-implant interface were visualized.In the neutrally aligned tibial and talar TAR models, peak contact pressures of respectively 98.4 MPa and 68.2 MPa, and shear stresses of respectively 49.3 MPa and 39.0 MPa were found. TAR malalignment increases peak contact pressure and shear stress on the bone-implant interface. A maximum peak contact pressure of 177 MPa was found for the 10° valgus malaligned tibial component and the highest shear stress found was 98.5 MPa for the 10° posterior malaligned talar model.Upon TAR malalignment contact stresses increase substantially, suggesting that proper orientation of the TAR is needed to minimize peak stresses on the bone-implant interface. This is in line with previous studies, which state that malalignment considerably increases bone strains, micromotion, and internal TAR contact pressures, which might increase the risk of TAR failure. Further research is needed to investigate the relationship between increased contact stresses at the bone-implant interface and TAR failure.
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