Biomechanical evaluation of bending strength of spinal pedicle screws, including cylindrical, conical, dual core and double dual core designs using numerical simulations and mechanical tests

Pedicle screws are used for treating several types of spinal injuries. Although several commercial versions are presently available, they are mostly either fully cylindrical or fully conical. In this study, the bending strengths of seven types of commercial pedicle screws and a newly designed double dual core screw were evaluated by finite element analyses and biomechanical tests. All the screws had an outer diameter of 7 mm, and the biomechanical test consisted of a cantilever bending test in which a vertical point load was applied using a level arm of 45 mm. The boundary and loading conditions of the biomechanical tests were applied to the model used for the finite element analyses. The results showed that only the conical screws with fixed outer diameter and the new double dual core screw could withstand 1,000,000 cycles of a 50–500 N cyclic load. The new screw, however, exhibited lower stiffness than the conical screw, indicating that it could afford patients more flexible movements. Moreover, the new screw produced a level of stability comparable to that of the conical screw, and it was also significantly stronger than the other screws. The finite element analysis further revealed that the point of maximum tensile stress in the screw model was comparable to the point at which fracture occurred during the fatigue test.