Evaluation of sequentially crosslinked ultra-high molecular weight polyethylene

This study was undertaken to investigate the effect of crosslinking ultra‐high molecular weight polyethylene (UHMWPE) in a sequential manner to the final desired dose and to compare the results to single‐dose crosslinking. To verify these results, an explanted, commercially available, sequentially crosslinked component was characterized. Finally, additional tensile testing was conducted to determine if tensile‐sample thickness has a significant effect on the mechanical properties of UHMWPE. Based upon this well‐controlled study with the same starting material, there is no apparent benefit of sequential crosslinking over crosslinking by single dose in any of the mechanical, thermophysical, physical, or oxidative properties evaluated in this study. In contrast, the soak temperature of the postirradiation heat treatment was more influential and exhibited statistically significant effects on the stability, structure, and properties of the resultant material. Compared to virgin material, crosslinking always resulted in decreases in tensile strength, elongation, and impact strength. These results were confirmed by characterization of a retrieved, sequentially crosslinked (X3™) cup. All of the metrics derived for the retrieved cup were virtually identical to the sequential‐ and single‐dose‐crosslinked materials produced in this study. Examination of the effect of tensile‐sample thickness demonstrated that there are significant effects on the resultant properties. In particular, the ultimate tensile strength of UHMWPE can be elevated by conducting tensile tests with thin specimens. © 2008 Wiley Periodicals, Inc. J Biomed Mater Res Part B: Appl Biomater, 2009