Additive manufactured push‐fit implant fixation with screw‐strength pull out

Additive manufacturing offers exciting new possibilities for improving long‐term metallic implant fixation in bone through enabling open porous structures for bony ingrowth. The aim of this research was to investigate how the technology could also improve initial fixation, a precursor to successful long‐term fixation. A new barbed fixation mechanism, relying on flexible struts was proposed and manufactured as a push‐fit peg. The technology was optimized using a synthetic bone model and compared with conventional press‐fit peg controls tested over a range of interference fits. Optimum designs, achieving maximum pull‐out force, were subsequently tested in a cadaveric femoral condyle model. The barbed fixation surface provided more than double the pull‐out force for less than a third of the insertion force compared to the best performing conventional press‐fit peg (p < 0.001). Indeed, it provided screw‐strength pull out from a push‐fit device (1,124 ± 146 N). This step change in implant fixation potential offers new capabilities for low profile, minimally invasive implant design, while providing new options to simplify surgery, allowing for one‐piece push‐fit components with high levels of initial stability.