This study examined tibiofemoral contact stresses in 15 commercially a
vailable TKR designs, using digitally imaged pressure-sensitive film.
The objectives were (1) to determine the correlation between minimizat
ion of spatial mean contact stress and minimization of the amount of o
verloaded (> 10 MPa) polyethylene contact area, and (2) to ascertain t
he difference in contact stresses for machined versus moulded polyethy
lene inserts. The data showed that there was no statistically signific
ant (design rank-order) correlation of spatial mean contact stress wit
h overloaded polyethylene area. The data also showed that machining cu
tter preparation of the polyethylene insert caused substantial local c
ontact stress non-uniformities that corresponded to the pattern of gro
ssly visible machining marks.