Superior fixation strength of coronoid process replacement using individually designed 3D printed prosthesis with curved cemented intramedullary stem

Abstract

Background: Coronoid fractures frequently occur as part of complex elbow injuries and account for 2%-15% of the cases with dislocations. Comminuted fractures and nonunions necessitate surgical treatment. Considering the latest technological advancements, the aim of this study was to investigate the fixation strength of coronoid replacement using an individualized 3D printed prosthesis with curved cemented intramedullary (IM) stem vs. both radial head grafted reconstruction and coronoid fixation.

Methods: Twenty-four human cadaveric paired forearms were stripped of soft tissue and their computed tomography scanned ulnas were randomized to 4 groups for coronoid replacement (prosthesis group), radial head grafted reconstruction (radial head group), fixation (fixation group), or no treatment (intact group). The ulnas in all groups, except the intact one, were osteotomized at 40% of the coronoid height and the coronoid process was either replaced with a 3D printed stainless-steel prosthesis with curved cemented IM stem individually designed based on the contralateral scan (prosthesis group), reconstructed with an ipsilateral radial head autograft fixed with 2 anteroposterior screws (radial head group), or fixed in situ with 2 anteroposterior screws (fixation group). All specimens were biomechanically tested under ramped quasistatic axial loading.

Results: Bone mineral density was not significantly different among the groups (P = .95). Stiffness and failure load in the prosthesis group was significantly higher compared to all other groups (P ≤ .04) and in addition, it was significantly lower in the fixation group compared to the intact group (P = .03), with no further detected significant differences among the groups (P ≥ .72). Absorbed energy to failure in the prosthesis group was significantly more compared to both radial head and fixation groups (P ≤ .04) but not vs. the intact group. Failure deformation at the osteotomy site was not significantly different among the groups (P = .26).

Conclusions: Coronoid process replacement using an anatomically shaped, individually designed 3D printed prosthesis with curved cemented IM stem seems to be an effective method to restore the coronoid buttress function under axial loading. This method provides superior fixation strength over both radial head grafted reconstruction and screw fixation.

Keywords: 3D printed; Elbow; biomechanical testing; biomechanics; coronoid; individual; prosthesis.