An Adaptable Ct-Derived 3D-Printed Alignment Fixture Minimizes Errors in Whole-Bone Biomechanical Testing

Biomechanical testing of long bones can be subject to undesirable errors and uncertainty due to malalignment of specimens with respect to the mechanical axis of the test frame. To solve this problem, we designed a novel, customizable alignment and potting fixture for long bone testing. The fixture consisted of 3D-printed components modeled from specimen-specific CT scans to achieve a predetermined specimen alignment. We demonstrated the functionality of this fixture by comparing benchtop torsional test results to specimen-matched finite element models and found a strong and statistically significant correlation (R2 = 0.9536, p < 0.001). Additional computational models estimated the impact of malalignment on mechanical behavior in both torsion and axial compression. Results confirmed that torsion testing is relatively robust to alignment artifacts, with absolute percent errors less than 8% in all malalignment scenarios. In contrast, axial testing was highly sensitive to setup errors, experiencing absolute percent errors up to 40% with off-center malalignment and up to 130% with angular malalignment. This suggests that whenever appropriate, torsion tests should be used preferentially as a summary mechanical measure. When more challenging modes of loading are required, pre-test clinical-resolution CT scanning can be effectively used to create potting fixtures that allow for precise pre-planned specimen alignment. This may be particularly important for more sensitive biomechanical tests (e.g. axial compressive tests) that may be needed for industrial applications, such as orthopaedic implant design.