An antioxidant stabilized, chemically cross-linked UHMWPE with superior toughness

Chemical cross-linking of ultrahigh molecular weight polyethylene (UHMWPE) using an organic peroxide followed by high temperature melting results in a large increase in toughness accompanied by a decrease in cross-link density, which, surprisingly does not compromise the wear resistance. We compared the mechanical properties and wear behavior of a vitamin E blended, chemically cross-linked and high temperature melted UHMWPE produced by ram extrusion (PRX HTM) to those measured with the clinically available 100-kGy irradiated and melted UHMWPE (CISM 100). We also assessed the local biocompatibility of PRX-HTM in rabbit subcutaneous pouch and osteochondral defect models. The ultimate tensile strength and pin-on-disc wear rate were similar to CISM 100; whereas the elongation-at-break and impact toughness were much higher with PRX-HTM. The stress intensity factor range at crack inception was also higher with PRX-HTM. Accelerated aging did not result in any measurable oxidation or changes in mechanical properties. Hip simulator wear rate of acetabular liners made with PRX-HTM was 0.3 ± 0.4 mg/million-cycle, similar to that reported for CISM 100 liners. The wear particles were largely spherical with a number-averaged particle size of 0.95 μm with ~75% of particles below 1 μm. The subcutaneous and osteochondral rabbit implantations showed no histological differences between PRX-HTM and the control CISM 100. Pre-clinical wear, mechanical, and biocompatibility testing of PRX HTM showed feasibility for the use of this material as a total joint arthroplasty implant bearing surface. This process has the potential of eliminating the additional step of radiation cross-linking by combining consolidation and cross-linking while improving toughness. © 2018 Wiley Periodicals, Inc. J Biomed Mater Res Part B: Appl Biomater 107B: 1945–1952, 2019.