Dose effects of cross‐linking polyethylene for total knee arthroplasty on wear performance and mechanical properties

Wear performance and mechanical properties of cross‐linking polyethylene (XLPE) tibial inserts were investigated using a knee simulator, scanning electron microscopy (SEM), and a small punch test (SPT). Ultrahigh molecular weight PE made from GUR1050 resin was irradiated at doses ranging from 0 to 200 kGy and then machined into tibial inserts followed by annealing. The knee simulator was run for up to four million cycles. As the radiation dose increased from 0 to 100 kGy, the wear rate decreased dramatically, yielding 95% wear reduction at 100 kGy. The microwear features observed by SEM supported the dose‐dependent wear reduction. The SPT for XLPE after the simulation test showed that, as the radiation dose increased from 0 to 200 kGy, the ultimate displacement decreased dose‐dependently, while the ultimate load increased from 0 to 75 kGy and decreased from 75 to 200 kGy. The resulting toughness of the PE increased to its maximum at a dose of 50 kGy and then decreased with higher doses up to 200 kGy. PE cross‐linked with radiation doses from 25 to 75 kGy had greater toughness than virgin, nonirradiated PE. However, PE irradiated with 100 kGy or more had lower toughness than virgin PE. These data suggest that a certain amount of irradiation enhances both wear performance and toughness of PE tibial inserts. Although a certain amount of cross‐linking would be effective for clinical application of PE tibial inserts, an optimal radiation dose should be much smaller than that used in current XLPE in total hip arthroplasty. © 2007 Wiley Periodicals, Inc. J Biomed Mater Res Part B: Appl Biomater, 2007