Fracture of Contemporary Femoral Stems: Common Trends in This Rare Occurrence

Background: Fracture of contemporary femoral stems is a rare occurrence in total hip arthroplasty. A knowledge gap remains regarding manufacturing, patient, and surgeon factors that may contribute to the increased risk of this complication. Methods: We analyzed 13 contemporary fractured porous-coated femoral stems of various designs to determine cause and contributing factors of mechanical failure. Cases included 12 men and 1 woman who had an average age at index surgery of 53 years (range, 34 to 76 years). There were 10 of 13 patients who had a body mass index more than 30 (obese); 3 of the 10 had a body mass index more than 40. The mean time to fracture was 7.6 years (range, 7 months to 12 years). Results: There were 4 titanium alloy stems that fractured an average of 3.6 years postrevision surgery for head/cup exchange and had associated iatrogenic mechanical and electrocautery damage to the femoral neck at fracture initiation sites. There were 6 modular stems that failed at the stem-sleeve or stem-neck interfaces with evidence of fretting corrosion. For 2 stem-neck fractures, mismatched head/stem combinations from different manufacturers resulted in untested mechanical offsets and loading. There were 2 proximal neck fractures and 1 mid-shaft fracture of coated cobalt-chromium alloy stems that occurred in 3 obese men. The neck fractures (10 to 12 years) were well-fixed stems. Lack of proximal fixation contributed to the mid-shaft fracture (7 months). Conclusion: While rare, femoral stem fractures pose catastrophic outcomes in primary and revision total hip arthroplasty. Manufacturing, patient, and surgical factors contributing to stem failures were identified, including patient obesity, heat-treatment reduction of mechanical properties, iatrogenic implant damage, and mixing of different vendor stems and heads.