Titanium Plasma Spray Coatings for Acetabular Components in Total Hip Arthroplasty: Influence of Coating Thickness on Implant Performance.

Dhananjaya Shukla; Vilas Khade

doi:10.69968/ijisem.2026v5i3576-584

Authors

Dhananjaya Shukla Research & Development Department, Alkem MedTech Pvt. Ltd., Mumbai, Maharashtra, India
Vilas Khade Research & Development Department, Alkem MedTech Pvt. Ltd., Mumbai, Maharashtra, India

DOI:

https://doi.org/10.69968/ijisem.2026v5i3576-584

Keywords:

Titanium plasma spray coating, Acetabular component, Total hip arthroplasty, Osseointegration, Surface engineering, Coating thickness optimization, Implant fixation, Porous titanium coating, Orthopaedic implants, Plasma spray technology

Abstract

Plasma-sprayed titanium (Ti) coatings are widely recognized as an effective surface engineering technology for acetabular components used in total hip arthroplasty (THA) due to their ability to enhance osseointegration, improve implant fixation, and support long-term clinical performance. The effectiveness of these coatings is strongly influenced by coating thickness, which plays a significant role in determining microstructural characteristics, adhesion behavior, stress distribution, and biological response. This study presents a comprehensive literature-based review of the influence of titanium plasma spray coating thickness on the functional performance of orthopaedic implant surfaces. Published scientific literature, supported by internal design considerations, was reviewed to evaluate thickness-dependent trends related to coating integrity, porous architecture, and implant stability.

The reviewed literature indicates that appropriately designed coating thickness can contribute to enhanced surface roughness, optimized pore interconnectivity, improved coating adhesion, and favorable conditions for bone ingrowth and long-term biological fixation. Literature findings further suggest that coating thickness in the range of approximately 200-300 µm provides a practical balance between mechanical stability and biological performance, supporting implant integration while maintaining coating integrity under physiological conditions. Advanced process control and optimized coating architecture have also been reported to improve coating reliability and overall implant functionality. In addition, recent developments in surface engineering, including functionally graded coatings, controlled porous structures, and advanced manufacturing technologies, have demonstrated significant potential for further enhancing coating performance and implant longevity. These approaches offer opportunities to optimize load transfer, improve biological interactions, and strengthen coating stability for next-generation orthopaedic implants.

In conclusion, titanium plasma spray coating thickness represents a key design consideration for achieving reliable mechanical performance and successful biological fixation in acetabular implant applications. The reviewed literature supports the continued implementation and optimization of titanium plasma spray coatings as an effective strategy for improving implant surface functionality and promoting long-term orthopaedic outcomes. Further experimental and clinical investigations may provide additional evidence to refine coating design parameters and support future advancements in implant surface technologies.

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