BackgroundAll current total hip arthroplasty (THA) systems are modular in design. Only during the operation femoral head and stem get connected by a Morse taper junction. The junction is realized by hammer blows from the surgeon. Decisive for the junction strength is the maximum force acting once in direction of the neck axis, which depends both on the applied impulse and the damping of human soft tissues. This leads to large differences in assembly forces between the surgeons. The investigation of assembly forces of different surgeons under influence of soft tissue damping is subject of this study.MethodsFirst, a measuring system, consisting of a prosthesis and a hammer, was developed. Both components are equipped with a piezoelectric force sensor. Initially, in situ experiments on human cadavers were carried out using this system in order to determine the actual assembly forces and to characterize the damping properties of human soft tissue. In addition to these experiments, an in vitro model in form of an artificial femur (Sawbones Europe AB, Malmo, Sweden) with implanted measuring stem embedded in gelatine was developed. The gelatine mixture was chosen in such a way that damping properties of the model correspond to those in situ. A study with 31 surgeons was carried out on the in vitro model mentioned above, in which the assembly forces were determined.ResultsA model has been developed, that represents the physiological damping behaviour of human soft tissue. The assembly forces measured on in vitro model were on average 2037.2 N ± 724.9 N and ranged from 822.5 N to 3835.2 N. The comparison of the surgeons showed no significant differences regarding sex (p=0.09), work experience (p=0.71) and number of THAs per year (p=0.69).ConclusionsAll measured assembly forces were below 4 kN, which is recommended in the literature. This could lead to increased corrosion following fretting in the head-neck interface. In addition, there was a very wide range of assembly forces among the surgeons, although other influencing factors such as different implant sizes or materials were not taken into account. To ensure optimal assembly force, the impaction should be standardized, e.g. by an appropriate surgical instrument.