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The current study was designed to compare the surface anatomy of the knee for different human subject anthropometries using a 3-D, non-contact digitizer which converted the anatomy into point clouds. The subjects were studied at flexion angles of 60, 90, and 120 degrees. Multiple subjects fitting narrow anthropometrical specifications were studied: 5th percentile female, 50th percentile male, and 95th percentile male. These data were then compared to a corresponding anthropometrical crash dummy knee which served as an unambiguous control. Intersubject human comparisons showed surface geometry variations which were an order of magnitude smaller than comparisons between the human and dummy knee. Large errors between the human and dummy were associated with the muscle bulk proximal and distal to the popliteal region and the rounder shape of the human knee.

Injuries to the lower extremities are common during car accidents because the lower extremity is typically the first point of contact between the occupant and the car interior. While injuries to the knee, ankle and hip are usually not life threatening, they can represent a large societal burden through treatment costs, lost work days and a reduced quality of life. The aim of the current study was to specifically study injuries associated with the knee and to propose a methodology which could be used to prevent future knee injuries. To understand the scope of this problem, a study was designed to identify injury trends in car crashes for the years 1979-1995. The NASS (National Accident Sampling System) showed that 10% of all injuries were to the knee, second only to head and neck injuries. Most knee injuries resulted from knee-to-instrument panel contact. Subfracture injuries were most common (contusions, abrasions, lacerations) followed by gross fracture injuries.

Contact between the knees and knee bolster commonly occurs in frontal collisions. The contact region on the bolster and the knee anatomy involved are related to the pre-crash positioning of the knees. The location of the distal (or infra-) patella was recorded on volunteers of widely varying stature after they had selected a comfortable driving position in mockups of three vehicles representing a large variation in size and shape: sedan, crossover SUV, and full-size pickup. On average, the right knees were grouped more tightly and were located more forward and lower than the left knees. On average, the knees were positioned 200 mm from the knee bolster for all subjects. The range of distance separating the distal patellae (within subject knee-to-knee distance) varied from 184–559 mm for all subjects for the three vehicles.

Numerous studies have documented the implantation of a 6-axis load cell in series with the tibial shaft and a limited number of studies have instrumented the femur for uniaxial load transduction. We are unaware of a single study seeking to instrument both anatomical segments. In addition, while the instrumentation processes have been described in textural and graphical detail, the dimensions and material choices for preparation jigs, potting cups, etc. are typically not given. In the current study, we have reviewed the available literature and have developed a modified preparation and implantation methodology. We also include complete designs appropriate for a reproduction of our process or modification of the methodology by the reader. The robustness of our technique was verified in a companion study in which whole, unembalmed cadavers were subjected to a HYGE frontal sled test without compromise of the instrumentation.

Numerous studies have documented that lower extremity injury is second only to the head and face in automotive accidents. Such injuries are common because the lower extremity is typically the first point of contact between the occupant and the car interior. Of all lower extremity injuries, the knee is the most common site of trauma. This typically results from high speed contact with the instrument panel which can produce fracture and subfracture (contusions, lacerations, abrasions) level injuries. Current Federal safety guidelines use a bone fracture criterion which is based solely on a peak load. The criterion states that loads exceeding 10 kN will likely result in gross bone fracture. However, cadaver experiments have shown that increased contact area (via padding) over the knee can significantly increase the amount of load that can be tolerated before fracture or subfracture injury.