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Additive manufactured osseointegrated screws with hierarchical design

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Abstract

Bone screws are devices used to fix implants or bones to bones. However, conventional screws are mechanically fixed with thread and often face long-term failure due to poor osseointegration. To improve osseointegration, screws are evolving from solid and smooth to porous and rough. Additive manufacturing (AM) offers a high degree of manufacturing freedom, enabling the preparation of predesigned screws that are porous and rough. This paper provides an overview of the problems currently faced by bone screws: long-term loosening and screw breakage. Next, advances in osseointegrated screws are summarized hierarchically (sub-micro, micro, and macro). At the sub-microscale level, we describe surface-modification techniques for enhancing osseointegration. At the micro level, we summarize the micro-design parameters that affect the mechanical and biological properties of porous osseointegrated screws, including porosity, pore size, and pore shape. In addition, we highlight three promising pore shapes: triply periodic minimal surface, auxetic structure with negative Poisson ratio, and the Voronoi structure. At the macro level, we outline the strategies of graded design, gradient design, and topology optimization design to improve the mechanical strength of porous osseointegrated screws. Simultaneously, this paper outlines advances in AM technology for enhancing the mechanical properties of porous osseointegrated screws. AM osseointegrated screws with hierarchical design are expected to provide excellent long-term fixation and the required mechanical strength.

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(Reproduced from https://si-bone.com/providers/solutions/pelvic-trauma/ifuse-torq, with permission from SI-BONE). d5 Photograph of AM osseointegrated screw for sacroiliac fusions (3D Printed implants, Genesys SIros™, Texas, USA) (Reproduced from https://www.genesysspine.com/products/sacral/lateral-sacroiliac-joint-fusion-siros-3d-printed/, with permission from Genesys). d6 Photograph of AM osseointegrated screw for sacroiliac fusions (3D™ SI Joint Fusion System, Cornerloc TransLoc, Oklahoma, USA) (Reproduced from https://cornerloc.com/transloc-3d/, with permission from Cornerloc). d7 Photograph of AM osseointegrated screw for sacroiliac fusions (FIREBIRD SI Fusion System, Orthofix, Texas, USA) (Reproduced from https://orthofix.com/products/spine-solutions/spine-procedures/si-fusion/firebird-si-fusion-system/, with permission from Orthofix). d8 Photograph of AM osseointegrated pedicle screw (Bi-Cortical/Mid-Line Porous Cannulated screw, Tsunamimedical, Ventotene, Italy) (Reproduced from https://www.tsunamimedical.com/product-category/spine/pedicle-screw-systems/modular-pedicle-screw-shafts/, with permission from Tsunamimedical). d9 Photograph of AM osseointegrated pedicle screw (Porous Cannulated screw, Tsunamimedical, Ventotene, Italy) (Reproduced from https://www.tsunamimedical.com/product-category/spine/pedicle-screw-systems/modular-pedicle-screw-shafts/, with permission from Tsunamimedical)

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Acknowledgements

This work was supported by the National Natural Science Foundation of China (Nos. 82272504 and 82072456), the National Key R&D Program of China (No. 2018YFB1105100), the Department of Science and Technology of Jilin Province, China (Nos. 20200404202YY, 20200403086SF, 20210101321JC, 20210204104YY, 20200201453JC, 20220204119YY, 202201ZYTS131, 202201ZYTS129, 20220401084YY, 202201ZYTS505, and YDZJ202301ZYTS076], the Department of Finance of Jilin Province, China (No. 2020SCZT037), the Jilin Provincial Development and Reform Commission, China (Nos. 2018C010 and 2022C043-5], the Interdisciplinary Integration and Cultivation Project of Jilin University (No. JLUXKJC2020307), and the Central University Basic Scientific Research Fund (No. 2023-JCXK-04].

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  1. Wenbo Yang and Hao Chen have contributed equally to this work.

Authors and Affiliations

  1. Department of Orthopedics, Second Hospital of Jilin University, Changchun, 130022, China

    Wenbo Yang, Hao Chen, Haotian Bai, Yifu Sun, Aobo Zhang, Yang Liu, Qing Han & Jincheng Wang

  2. College of Biological and Agricultural Engineering, Jilin University, Changchun, 130022, China

    Yuchao Song

  3. School of Materials Science and Engineering, Jilin University, Changchun, 130022, China

    Yuchao Song

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Contributions

WBY investigated and summarized the literature, drew the graphs, and wrote the original draft. HC conducted deep review and editing. HTB and YFS conducted deep review. ABZ, YL, and YCS gave some advice. QH and JCW helped revise the paper, supervised the work, and applied for funds. All authors have read and approved this manuscript for publication.

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Correspondence to Qing Han or Jincheng Wang.

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Yang, W., Chen, H., Bai, H. et al. Additive manufactured osseointegrated screws with hierarchical design. Bio-des. Manuf. 7, 206–235 (2024). https://doi.org/10.1007/s42242-024-00269-3

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