Wire tensioning with integrated load-cell in the Ilizarov orthopedic external fixation system

A new K-wire gripping configuration of the Ilizarov wire tensioning and hold assembly with an integrated load-cell is presented here. The method addresses two critical issues that appear in K-wire clamping assemblies in use, slippage and re-tensioning, being the major shortcomings of the standard fixation methods. The new grip can be re-tensioned by the patient, according to the load-cell measurements and the physician's instructions. The new design provides the advantages of a more accurate axial alignment of the K-wires, limited prestress loss, and lack of slippage. Detailed design with a commercially available solid modeling software and spread-sheet computation capability offers design flexibility for custom made solutions to adapt different patient's needs. Full-ring Ilizarov frame applied for lengthening of tibia (upper), wire fixation methods (a) slotted bolt-head wire fixation, b) cannulated wire fixation (lower) and (c) the new grip assembly with an integrated load sensor and wire tension adjustment nut. [Display omitted] •A new design for the Ilizarov's fixator K-wire clamping assembly•Accurate axial alignment and tensioning of the K-wires•Experimental evaluation•Precise adjustment of K-wires by the patient•Consistent mechanism design and synthesis methodology