Six vacuum mixing systems, Cemvac, Merck, Mitvac, Optivac, Osteobond, and Stryker, were tested using prechilled Palacos R bone cement to investigate the reduction of porosity compared to mixing at atmospheric pressure. In addition the Optivac, Osteobond, and Stryker were tested using Simplex P bone cement to find out if they were effective in reducing the porosity of a middle viscosity bone cement. All vacuum mixing systems reduced the number of macropores (> 1 mm) and micropores (0.1 mm < voids < 1 mm) and increased the density of both Palacos R and Simplex P. But only the Optivac, Stryker, and Merck systems reduced the area percentage of macropores with more than 50% compared to the control. When using Simplex P bone cement, all three mixing systems tested reduced the numbers and the area percentage of macropores compared to the control. The results show that vacuum mixing is effective in reducing the porosity in both a high viscosity cement such as Palacos R and a middle viscosity cement such as Simplex P. Not all systems tested were effective in reducing the number and size of large voids.

We developed a prepacked mixing system for the preparation of bone cement. The system is based on mixing and collection of bone cement under a vacuum and serves as both the storage and mixing device for the cement components, thereby minimizing the exposure of the operating staff to the monomer and the risk for contamination of the cement during preparation. We evaluated the system using Palacos R and Simplex P. The cement produced was compared with cement obtained from a commercially available mixing system. Temperature evolution during curing, handling characteristics, density, and porosity of the cement obtained were analyzed. The results showed that the experimental system produces cement with physical properties (i.e., setting times and temperature, porosity, and density) equal to or better than those obtained with commercially available systems. Reducing the amount of monomer in the experimental system led to a reduction of the curing temperature without compromising the physical properties of the cements.