Degenerative disc disease of the cervical spine is a highly prevalent condition, commonly requiring surgical intervention. While anterior cervical discectomy and fusion (ACDF) has long been the surgical standard of care, its limitations, including degeneration of the adjacent segments and complete loss of motion, have prompted the development of alternative solutions. Notably, cervical disc replacements (CDRs) were introduced to preserve the range of motion and reduce the likelihood of adjacent segment degeneration. However, despite their increase in popularity, clinical outcomes have indicated that mechanical failure of these devices can lead to early revision surgery.Based on the available clinical data, one of the most frequently reported mechanical causes for CDR removal is loosening and/or migration. In large joint arthroplasty, it is typically reported that relative cyclic motions between the bone-implant interface need to be below 40–150um to achieve successful long-term fixation. Failure to meet this threshold can lead to migration of the implant over time, resulting in an increase likelihood of implant failure. Specifically, migration- related failures are the leading cause of cervical device revisions cases, with 84% of CDR revisions and 96% of all adverse events being removed due to migration as reported in the FDA adverse event reporting database. Moreover, specific devices vary substantially in the reported rates of migration-related reasons for failure. Interestingly, these devices can vary widely in design features that could affect bony fixation and stability.
Unfortunately, current preclinical testing may not be adequate in addressing implant fixation with relatively few biomechanical studies evaluating CDR fixation in the literature. In contrast, studies of loosening and migration have formed the cornerstone for preclinical testing of arthroplasty implants in the hip and knee. These studies have successfully predicted the clinical performance of joint replacements. Typically, investigations of migration in large joint literature utilizes composite long bones, which have been made commercially available. However, no such model exists for the cervical spine. The absence of a validated biomechanical testing model may have led to this lack of migration studies over the last two decades for CDR, representing a major deficiency in the current field of spine arthroplasty.
Therefore, the overall objective of this dissertation is to develop comprehensive testing methodology to evaluate cervical device fixation and initial implant stability, through the fabrication of an in vitro biomimetic model and analysis of current devices for the relative contributions of specific design features to the overall stability of the device. Accordingly, this dissertation is the first step in developing a protocol to systematically assess fixation of CDRs.
Chapter 1: Retrieval Analysis
A retrieval analysis conducted as the first component of this dissertation established a clinical record of migration-related failures in current cervical disc replacements. Specifically, analysis of explanted devices revealed a significantly higher incidence of anterior migration in a ball-and-socket design compared to a fixed-core counterpart. These findings highlighted the role of implant design features in influencing fixation and stability. This clinical insight motivated the development of a preclinical testing platform to systematically assess the biomechanical behavior of CDRs under physiologic loading conditions.
Chapter 2: Creation of a 3D-Printed Model
To address the lack of established preclinical models for evaluating cervical implant fixation, a novel 3D-printed cervical vertebral body model was developed and validated. This biomimetic model featured a nonhomogeneous cancellous core designed to replicate the ultrastructure and material properties of human cervical bone. A range of lattice architectures and material densities were explored to produce a tunable and cost-effective platform for biomechanical testing. Uniaxial compression and shear testing confirmed that the model could replicate the load response of cervical bone, though limitations in replicating viscoelastic and ductile properties remain.
Chapter 3: Comparison of a 3D Model and Polyurethane Foam Model
The 3D-printed model created in chapter 2 was then benchmarked against a rigid polyurethane foam model, commonly used to simulate cancellous bone in long bone models, to assess their respective abilities to predict clinical performance. Through micromotion testing of multiple CDR designs the rigid polyurethane foam model was more sensitive in detecting differences in clinical observed migration and micromotion differences observed in retrieval data in chapter 1, suggesting it may be better suited for distinguishing clinical performance outcomes across varying implant designs. However, the 3D-printed model exhibited superior consistency and repeatability across trials. These findings underscore a trade-off between sensitivity and reliability in model selection and suggest that each platform offers distinct advantages. The foam model may be more appropriate for comparative micromotion testing across devices, while the 3D-printed model provides a robust and reproducible framework for future development of more accurate testing models.
Chapter 4: Micromotion Testing of Five Different Cervical Device Designs
Five distinct cervical disc replacement designs were evaluated using the validated testing model under both singular and combined loading conditions. Device design characteristics such as keel height, articulation type, ball-and-socket contact arc, and ball coverage angle were measured for each device and motions were assessed as a function of each feature. The results demonstrated that larger keel heights, smaller ball contact arcs, and greater ball coverage angles significantly reduced micromotion at the bone-implant interface. These findings suggest that specific implant geometries play a critical role in achieving primary stability and minimizing the risk of migration, which could inform future device design and regulatory approval pathways.
This dissertation addresses a critical clinical need in cervical spine arthroplasty literature by developing a methodology for preclinical testing to evaluate the contribution of implant design features to overall device stability. By integrating clinical retrieval data with in vitro testing, this work establishes a comprehensive protocol for assessing fixation-related design features in CDRs. The insights gained offer a roadmap for improving implant design, predicting long-term clinical performance, and refining preclinical testing standards, ultimately contributing to safer and more reliable cervical spine arthroplasty solutions.