The microstructure of ultra-high molecular weight polyethylene used in total joint replacements

The microstructure of ultra-high molecular weight polyethylene (UHMWPE) has been studied using a range of techniques. Both the unprocessed base powder and ram-extruded polymer have been examined using optical microscopy, scanning and transmission electron microscopy and smallangle light scattering. By examining the microstructure of samples compression moulded at a range of temperatures, techniques have been developed to assess the degree of consolidation of the processed polymer. The raw polymer is a powder with a particle size in the range 50–250 μm. These particles are themselves agglomerates of much finer particles typically 0.5–1 μm in size. It has been suggested that these sub-micron particles may be the origin of the sub-micron wear debris found in tissues around total joint replacements. However, examination of the ram-extruded polymer, from which implants are machined, shows a different structure from the powder, with no evidence of retention of the 0.5–1 μm structure seen in the powder in the processed material. It thus appears that the similarity in size between the sub-micron wear debris particles and the fine structure seen in the unprocessed UHMWPE resin is coincidental. Processed UHMWPE does show a ‘memory’ of the grain boundaries between powder particles and the degree of consolidation can be assessed by observing the distinctiveness of these boundaries.