Direct Compression Molded Polyethylene for Total Hip and Knee Replacements

Direct compression molded polyethylene is a process of creating a net-shaped component with finished articular surfaces from ultrahigh molecular weight polyethylene by applying heat and pressure to the raw resin (usually Hi-fax 1900) with the use of fixed geometry metallic tools. The final product has no machining or finishing. Sterilization was by gamma radiation in air. Between 1974 and 1978, there were 378 cemented T-28 stems (321 patients) and 171 cemented TR-28 stems (158 patients) articulating with a cemented direct compression molded acetabular component. Radiographically, linear wear was 0.06 mm per year for the T-28 stem and 0.05 mm for the TR-28 stems. The revision rates for the acetabulum were 9.5% and 7.9%, respectively with only two acetabula having osteolysis. On the femoral side, the revision rates were 11.1% and 12.8%, with 11 cases and one case of osteolysis, respectively. Between 1983 and 1996, 4583 AGC cemented total knee replacements were done with direct compression molded nonmodular tibial components. There was no osteolysis seen in these nonmodular compression molded total knee replacements even with 0.1% failure of the femoral components and 0.4% failure of the tibial components. Failure of all of the hip and knee implants was because of poor cement technique, instability, or both. Wear and osteolysis were minimal. Direct compression molded polyethylene has stood the test of time and is a good choice among the currently available polyethylenes.