Comparative evaluation of in vitro mechanical properties of different designs of epoxy-pin external skeletal fixation systems.

Objectives: To compare in vitro biomechanical properties of different designs of epoxy-pin external skeletal fixator (ESF) constructs.

Study Design: Mechanical testing study.

Sample Population: Four epoxy-pin ESF design constructs (uniplanar [EU], multiplanar-I [EM-I], multiplanar-II [EM-II], and circular [EC]) were mechanically tested in compression, bending, and torsion.

Methods: Four different designs of free-form epoxy-pin external fixator constructs were developed using 1.5 mm K-wires and epoxy resin mounted in an ultra-high density polyethylene rod (20 mm diameter). Three-point fixation was done in each fragment, and the distance between fixation wires, and between the rod and the side bars was kept constant in all the designs. A 5 mm gap was maintained at the center of the fixation rod to simulate an unstable fracture condition. The fixator constructs (n = 12 of each design) were subjected to mechanical testing in axial compression, bending, or torsion. Load-deformation curves were generated and mechanical properties were compared between construct types.

Results: EU was the weakest design. Under compression, constructs EM-I, EM-II, and EC were similar. Under bending, EM-I and EM-II had similar strength, whereas EC was strongest. Under torsion, EC was strongest, followed by EM-II, EM-I, and EU; EM-II provided double the rotational stability of EM-I.

Conclusions: Overall, EC followed by EM-II epoxy-pin fixator designs had better mechanical strength.