Introduction: Revision surgery of a previous lumbosacral non-union is highly challenging, especially in case of complications, such as a broken screw at the first sacral level (S1). Here, we propose the implementation of a new method based on the CT scan of a clinical case using 3D reconstruction, combined with finite element analysis (FEA), computer-assisted design (CAD), and 3D-printing technology to provide accurate surgical navigation to aid the surgeon in performing the optimal surgical technique by inserting a pedicle screw at the S1 level.Materials and Methods: A step-by-step approach was developed and performed as follows: (1) Quantitative CT based patient-specific FE model of the sacrum was created. (2) The CAD model of the pedicle screw was inserted into the sacrum model in a bicortical convergent and a monocortical divergent position, by overcoming the geometrical difficulty caused by the broken screw. (3) Static FEAs (Abaqus, Dassault Systemes) were performed using 500 N tensile load applied to the screw head. (4) A template with two screw guiding structures for the sacrum was designed and manufactured using CAD design and 3D-printing technologies, and investment casting. (5) The proposed surgical technique was performed on the patient-specific physical model created with the FDM printing technology. The patient-specific model was CT scanned and a comparison with the virtual plan was performed to evaluate the template accuracyResults: FEA results proved that the modified bicortical convergent insertion is stiffer (6,617.23 N/mm) compared to monocortical divergent placement (2,989.07 N/mm). The final template was created via investment casting from cobalt-chrome. The template design concept was shown to be accurate (grade A, Gertzbein-Robbins scale) based on the comparison of the simulated surgery using the patient-specific physical model and the 3D virtual surgical plan.Conclusion: Compared to the conventional surgical navigation techniques, the presented method allows the consideration of the patient-specific biomechanical parameters; is more affordable, and the intraoperative X-ray exposure can be reduced. This new patient- and condition-specific approach may be widely used in revision spine surgeries or in challenging primary cases after its further clinical validation.

Finite element (FE) analyses contribute to a better understanding of the human lumbar spine’s biomechanics and serve as an effective predictive tool. This study aims to present the development of two L1–L5 FE models using literature-based (LBM) and patient-specific (PSM) bone material assignment approaches. The geometry of the lumbar spine was developed based on quantitative computed tomography scans. The LBM and the PSM were compared under pure and combined loads. Various biomechanical parameters were investigated to validate the models. The total range of motion of the LBM in pure flexion-extension, lateral bending, and axial rotation were 30.9°, 29°, and 13.7°, respectively, while for the PSM, it was 31.6°, 28.6°, and 14.1°. The required computational time of the PSM to complete against pure and combined loads were 12.1 and 16.6 times higher on average compared to the LBM. This study demonstrated that both models agree with experimental and in silico results, although the cumulative distribution of the stress and characterization of strain values showed a noteworthy difference between the two models. Based on these findings, the clinically-focused biomechanical FE studies must perceive the differences in internal mechanical parameters and computational demand between the different bone modelling approaches.

OBJECTIVE Proximal junctional kyphosis (PJK) is a relatively common complication following long instrumented posterior spinal fusion. Although several risk factors have been identified in the literature, previous biomechanical studies suggest that one of the leading causes is the sudden change in mobility between the instrumented and noninstrumented segments. The current study aims to assess the biomechanical effect of 1 rigid and 2 semirigid fixation techniques (SFTs) on developing PJK. METHODS Four T7–L5 finite element (FE) models were developed: 1) intact spine; 2) 5.5-mm titanium rod from T8 to L5 (titanium rod fixation [TRF]); 3) multiple rods from T8 to T9 connected with titanium rod from T9 to L5 (multiple-rod fixation [MRF]); and 4) polyetheretherketone rod from T8 to T9 connected with titanium rod from T9 to L5 (PEEK rod fixation [PRF]). A modified multidirectional hybrid test protocol was used. First, a pure bending moment of 5 Nm was applied to measure the intervertebral rotation angles. Second, the TRF technique’s displacement from the first loading step was applied to the instrumented FE models to compare the pedicle screw stress values in the upper instrumented vertebra (UIV). RESULTS In the load-controlled step, at the upper instrumented segment, the intervertebral rotation values relative to TRF increased by 46.8% and 99.2% for flexion, by 43.2% and 87.7% for extension, by 90.1% and 137% for lateral bending, and by 407.1% and 585.2% for axial rotation, in the case of MRF and PRF, respectively. In the displacement-controlled step, maximum pedicle screw stress values at the UIV level were highest in the case of TRF (37.26 MPa, 42.13 MPa, 44.4 MPa, and 44.59 MPa for flexion, extension, lateral bending, and axial rotation, respectively). Compared to TRF, in the case of MRF and PRF, the screw stress values were reduced by 17.3% and 27.7% for flexion, by 26.6% and 36.7% for extension, by 6.8% and 34.3% for lateral bending, and by 49.1% and 59.8% for axial rotation, respectively. CONCLUSIONS FE analysis has shown that the SFTs increase the mobility at the upper instrumented segment and therefore provide a more gradual transition in motion between the instrumented and rostral noninstrumented segments of the spine. In addition, SFTs decrease the screw loads at the UIV level and hence could help reduce the risk for PJK. However, further investigations are recommended to evaluate the long-term clinical usefulness of these techniques.