Evaluating the suitability of highly cross-linked and remelted materials for use in posterior stabilized knees

Posterior stabilized (PS) knee designs are a popular choice for cruciate sacrificing knee arthroplasty procedures. The introduction of PS inserts fabricated from highly cross‐linked and remelted Ultra High Molecular Weight Polyethylene (UHMWPE) has recently generated concern as these materials have been shown to possess reduced mechanical properties. This study investigated whether highly cross‐linked and remelted UHMWPE material (referred to as XRP) can be expected to perform similarly to historical gamma‐air polyethylene, which has suffered few reported incidences of tibial post failure. Never‐implanted gamma‐air PS tibial inserts shelf‐aged 14 years were examined and compared to XRP materials. Evaluation of oxidation levels, impact toughness, and fatigue strength demonstrated never‐implanted gamma‐air PS tibial inserts to possess nonuniform mechanical properties. Despite severe oxidation along the exterior of gamma‐air tibial posts, comparatively low oxidation levels at the center of the tibial posts corresponded to sufficiently high mechanical properties. XRP material (75 kGy) showed superior impact toughness over shelf aged gamma‐air material; however, tibial post fatigue testing demonstrated XRP material (100 kGy) to be less resistant to fatigue failure than historical gamma‐air material. Results from this study indicate that XRP materials (100 kGy) may demonstrate an inferior resistance to tibial post failure than historical polyethylene. © 2010 Wiley Periodicals, Inc. J Biomed Mater Res Part B: Appl Biomater, 2010