Selection of Materials and Manufacturing Processes for Total Hip Arthroplasty ComponentsPages 409-425
Milan Ivkovic Abstract:
This study assessed material and process options for the femoral component, femoral head, and acetabular liner, excluding the outer acetabular cup. Materials were screened for biocompatibility, chemical and corrosion resistance, and load-bearing capacity, then compared using component-specific criteria. CES Selector (CES EduPack 2013) screened shaping and finishing processes. Outputs were checked against material-specific processing constraints, and relative unit-cost trends were examined by batch size. Ti-6Al-4V was selected for femoral component process analysis, while Co-Cr-Mo was retained as an alternative. Forging had a lower relative unit-cost index than HIP. For the femoral head, Al₂O₃ and ZrO₂ were retained for process analysis. BIOLOX® Delta was assessed within the technical-ceramic group, and Co-Cr-Mo was retained as a metallic alternative. Pressing and sintering or powder injection molding (PIM), followed by grinding, were identified. UHMWPE was selected for the acetabular liner, and HXLPE was considered a modified variant. Generic screening identified injection molding, which was not directly adopted for medical-grade UHMWPE. The retained routes were compression molding or ram extrusion of semi-finished stock, followed by precision machining. Together, the results support component-specific choices. Experimental validation and production data are needed to confirm feasibility and estimate actual costs.
Keywords:
Total hip arthroplasty,
Femoral component,
Femoral head,
Acetabular liner,
Biomaterials,
Manufacturing processes,
Process selection,
UHMWPE
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