The different failure modes of the connecting elements of the modular hip arthroplasty revision stem Revitan.

Abstract Introduction Fracture of the femoral stem is the cause of ~1 % of revisions after total hip arthroplasty. The risk increases intrinsically with modularity, whereby modularity is particularly useful in revision arthroplasty. We present 7 cases of failure of a specific modular, tapered, fluted, titanium alloy Revitan stem and analyse the different failure modes. Methods Retrospective review of all Revitan stems revised at our institutions due to implant failure and analysis of clinical presentation, diagnostic workup, and failure mode. The retrieved components were analyzed by optical and scanning electron microscopy. Results A total of 7 cases were included. There was a significant time lag between symptom onset and correct diagnosis. Conventional radiographs and low-dose CT scans (CT scout imaging) were decisive for diagnosis. All failures occurred at the level of the connection between the proximal component and the distal part of the stem. Three different failure modes were identified: loosening of the proximal component, fatigue fracture of the connection pin, and distal loosening of the connection pin. No alterations of the microstructure or deviation from manufacturing specifications regarding dimensions were observed. Failure was caused by mechanical overload. Conclusion Conventional radiographs are the mainstay in identifying failed modular stems. Repeated radiographs and low-dose CT scans may be helpful additions. No single modification of the connection will address all possible failure modes. Modularity of revision stems offers advantages up until insertion of the definitive stem. Monoblock definitive stems might overcome the potential mechanical weaknesses of modularity and should be considered in relatively young, heavy and active patients.