In total knee arthroplasty (TKA) using patient-specific instrumentation (PSI), the correlation between the preoperative surgical plan and intraoperative resection size is unclear. The aims of this study were to evaluate whether the computed tomography (CT)-based PSI surgical plan can be executed accurately and to determine the accuracy of bone resection in TKA using PSI.
Data of 45 consecutive knees undergoing TKA using CT-based PSI were retrospectively evaluated. The preoperative plan was prepared using three-dimensional CT acquisitions of the hip, knee, and ankle joints. Resected bone thicknesses of the femoral condyle of the distal medial, distal lateral, posterior medial, posterior lateral, and medial and lateral tibial plateaus were measured with a Vernier caliper intraoperatively. Then these respective measurements were compared with those in the preoperative CT-predicted bone resection surgical plan, and the measured thickness of resection was subtracted from the planned resection thickness. Errors were defined as: acceptable, ≤ 1.5 mm; borderline, 1.5-2.5 mm; and outliers,  > 2.5 mm.
Overall, 22 (48.9%) knees had no outliers. There were 20 (44.4%) and 3 (6.7%) knees in which only 1 and 2 resection planes were outliers, respectively. The posterior medial tibial plateau had the lowest proportion of acceptable cuts (44.4%). Posterior femoral resection including the medial and lateral condyles had more outliers (n = 18/90 cuts, 20.0%) (p < 0.001) than the tibial condyles (n = 3/90 cuts, 3.3%) and distal femoral cuts (n = 6/90 cuts, 6.7%). The posterior surface of the femur, where the incidence of outliers was higher, tended to have a higher proportion of undercuts than other surfaces of the femur (> 80%).
PSI showed only fair-to-moderate accuracy. The cutting guide for the posterior femur was less accurate than that for the tibia and distal femur. Specific attention is required when cutting the posterior femur. The PSI design needs to be improved to reduce errors.