Engagement and Stress Concentration Evaluation of a Novel Two-Part Compression Screw: A Preliminary Finite Element Analysis

<b>Background/Objectives:</b> This novel compression screw design offers potential benefits due to its two-part structure and can be used for various bone types, much like a conventional single-piece compression screw. However, full engagement may not always occur after final compression in clinical practice. This study aimed to verify the hypothesized optimal mechanical strength when the two parts are nearly fully combined and to determine a recommended engagement range based on stress distribution and concentration using finite element analysis. <b>Methods:</b> Ten models representing different combinations of the two screw parts (ranging from 10% to 100% of the engagement length, at 10% intervals) were simulated to determine the acceptable engagement percentage. Pull-out and bending load simulations were performed using finite element models. Extreme clinical loading conditions were simulated, including 1000 N pull-out forces and a 1 Nm bending moment at the screw head. <b>Results:</b> Finite element analysis revealed two stress concentration points. The pull-out load simulation showed that combinations with 100% engagement merged the two stress concentrations into one without force superposition, while combinations with less than 30% engagement should be avoided. In the bending load simulation, higher stress was observed for combinations with less than 90% engagement. A lower level of engagement increases the bending moment, which might be the major factor affecting the von Mises stress. <b>Conclusions:</b> Surgeons should be instructed on how to use the screw correctly and select the most appropriate screw size or length for the two parts to achieve an effective combination. Excessive bending or pull-out forces, or improper use with poor combinations, may cause the middle interval to strip or the screw to break or pull out. An engagement of more than 90% is recommended, while less than 30% is considered dangerous. This study provides biomechanical insights into this novel two-part screw design and its important clinical implications.