The patient came to clinic with excessive hyperextension.Surgery was scheduled.When the implant was exposed it was noticed that pieces of polyethylene from the medial condyle bushing were fractured and free.The hinge connecting component was only partially engaged during revision surgery.The alignment (spring) hole in the medial retractable peg portion of the connecting component (the medial axis half) that designates its location when compared to the laser mark arrow on the connecting component was noticeably lateral to the arrow, suggesting that the medial peg was not fully engaged in situ.The lateral peg alignment hole was aligned with the lateral arrow on the connecting component, suggesting that it was at the time of explanting, engaged.The central connecting component screw that locks the medial and lateral pegs into a fully engaged position was notable proud, sitting 3-4 threads above its desired flush position.Whether the screw was engaged initially in the first procedure and loosened vs.Not being engaged at all was indeterminable.The surgeon removed the existing connection component and both polyethylene condyle bushings and replaced with new ones.Surgeon confirmed the set screw was slightly recessed and tight after part replacement.Range of motion was as it should be.Surgeon commented there was no noticeable metal debris.Note: this is not a new event.The manufacturer notified fda under mdr # 3004371426-2017-00002.
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