Finite element analysis of coated hip arthroplasty for enhanced implant longevity and sustainable orthopaedic design

Abstract Total hip arthroplasty (THA) remains a widely performed orthopaedic intervention; however, implant wear and limited longevity continue to drive revision surgeries, increasing both clinical burden and healthcare costs. This study presents a computational biomechanics framework to evaluate the influence of advanced surface coatings on wear behaviour and long-term performance of hip prostheses under physiological loading conditions. A three-dimensional finite element model of a femoral head–acetabular liner system was developed and subjected to dynamic gait cycle loading. Wear prediction was performed using an Archard-based model integrated within the simulation environment to quantify material loss over time. Three commonly used coatings—diamond-like carbon (DLC), titanium nitride (TiN), and aluminium oxide (Al₂O₃)—were systematically analysed in comparison with conventional bearing surfaces. The results demonstrate significant variation in contact stress distribution and wear rates across coating materials, with DLC-coated interfaces exhibiting the lowest wear and improved stress uniformity. TiN coatings showed moderate performance enhancement, while Al₂O₃ exhibited comparatively higher wear under cyclic loading conditions. The findings highlight the critical role of surface engineering in extending implant lifespan and reducing failure risk. By integrating computational modelling with wear prediction under realistic physiological conditions, this study provides a scalable approach for optimizing orthopaedic implant design. The proposed framework contributes to the development of durable and resource-efficient medical devices, supporting improved patient outcomes and advancing sustainable healthcare systems.