Exactech Modular Stem Stress Analysis
This study involved modeling and evaluating the structural performance of an Exactech AcuMatch M-Series Modular Stem used in total hip replacement surgeries. The goal was to identify stress concentrations associated with historical implant failures and explore geometry changes that could reduce stress in critical regions.
Technical Insights
Recreated the modular hip stem geometry using precise CAD references.
Encased the implant in a bone-cement layer to reflect realistic surgical fixation conditions.
Imported physiologically accurate loading profiles from orthoload.com to simulate joint forces.
Performed FEA to evaluate internal stress distributions, focusing on the implant neck and modular interface.
Design Highlights
Simulation revealed high stress concentrations at the neck — matching well-documented failure reports.
Iteratively increased neck diameter and offset to reduce peak stresses under load.
Generated clear visual FEA outputs illustrating load paths and comparative before-and-after improvements.
challenges and impact
Challenge: Representing cemented fixation mechanics accurately to avoid unrealistic constraint conditions.
Impact: Showed how subtle geometric adjustments can significantly improve implant safety and fatigue performance.
Reinforced the value of simulation-driven design refinement for long-term implant survivorship.
Skills and Tools
SolidWorks CAD · SolidWorks Simulation · FEA · Orthopedic Implant Analysis · Biomechanical Modeling · Failure Prediction · Product Improvement
Content
