Fixation of distal femoral osteotomy with an intramedullary rod: early failure of carbon fibre composite implant in rabbits.

A novel composite material with an ultra-high strength and a low elastic modulus, comprising a carbon fibre reinforced liquid crystalline polymer (LCP/CF) has been developed. An experimental osteotomy of the distal femur in nineteen rabbits weighing on average 4.8 (3.7-6.3) kg was fixed with an intramedullary LCP/CF rod of 3.2 mm in diameter and 50 mm in length. The initial mechanical properties of the rods had a mean shear strength of 180 MPa, a flexural strength of 450 MPa, and a flexural modulus of 40 GPa. The rods were implanted for periods of 3, 6, 12, 24, and 52 weeks. The healing of the osteotomy was analyzed by radiographic, histological, microradiographic, and oxytetracycline fluorescence studies. The strength retention of the LCP/CF rods was measured by mechanical testing. Solid union of the osteotomy was seen within 6 weeks. The implants retained their original strength properties up to 52 weeks. In three rabbits, a non-union with granulation tissue and carbon fibre particles was noticed at the osteotomy site, where disruption of the implant surface was seen at the level of the osteotomy. Further studies with a special interest in the fabrication process of the LCP/CF-implants are needed.