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Biocompatibility and
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ISBN: 978-0-08-102643-4 (print)
ISBN: 978-0-08-102644-1 (online)
If you want to build a ship, don’t drum up the men to gather wood, divide
the work, and give orders. Instead, teach them to yearn for the vast and
endless sea.
Antoine de Saint-Exupery
J.M. Anderson Case Western Reserve University, Cleveland, OH, United States
R.P. Brown Risk Science Consortium, LLC, Arnold, MD, United States
R.E. Geertsma National Institute for Public Health and the Environment (RIVM),
Bilthoven, The Netherlands
W.H. De Jong National Institute for Public Health and the Environment (RIVM),
Bilthoven, The Netherlands
followed, taking into account the principles of biological evaluation that have been
included in standards and guidance documents since 1979. These principles, which are
explained in Clause 4 of ISO 10993-1:2018, can be summarized as follows:
●
the importance of chemical characterization of a material;
●
the influence of components, residues, leachables and degradation products;
●
the need for good laboratory practice;
●
the need for evaluation by competent, informed people;
●
the need for full experimental data;
●
the need to evaluate any changes in chemical composition, processing, physical configura-
tion or intended use;
●
the need for the biological evaluation to be considered within the context of all relevant
information (e.g., bench and mechanical testing, preclinical performance studies, clinical
experience, postmarket surveillance data).
Annex E.3.c) of ISO DTR 24971:2019 (Guidance on the application of ISO 14971)
identifies the sort of data needed for a biological risk analysis, which comprise:
●
the physical and chemical characteristics of the materials;
●
the history of clinical use or data from human exposure;
●
existing toxicity data on components, and
●
biological safety data from test procedures carried out with materials and final products.
The way these types of data are used in the risk management process is explained
in Annex B of ISO 10993-1:2018, which provides guidance on the application of
ISO 14971 to the conduct of biological evaluation. The risk management process
starts with the identification of hazards; in this case, toxicological hazards arising
from the chemical constituents of a device and biological hazards arising from its
physical nature. The harm arising from such hazards can include adverse reactions
to materials, constituents or degradation products, or an inappropriate biological
response. A hazardous situation arises if a person is exposed to a toxicological or
physical hazard arising from the device. If a hazardous situation is identified, the
risk arising from the anticipated level, route and duration of exposure to the hazard
must be estimated and its acceptability assessed. However, if exposure to the hazard
is below a level that can cause harm to health, there is no risk and the process can
stop. So the quickest way to exit an evaluation can be to confirm that there is no haz-
ardous situation. Likewise, if risk control measures are needed, these are normally
targeted at preventing a hazardous situation arising, for example by eliminating a
source of toxicity or reducing exposure. Note that a hazardous situation only occurs
if the hazard is present at a level that can cause harm. A structured biological eval-
uation plan is a way of determining what additional datasets are needed to identify
hazards or estimate risks.
The reason material characterization is so important in a biological evaluation is
that it allows hazards to be identified, thus initiating the biological risk management
process. Hazard identification is arguably the most critical of all the risk management
steps. Once a hazard has been recognized, a manufacturer will take action to control
the risk. Thankfully very few problems have arisen as a result of toxicity arising from
a device but, where field safety action has been taken in response to toxic hazards,
Forewordxix
for example with toxic degradation products from soybean-filled breast implants or
aluminum leaching from IV fluid warmers, the situation occurred because the toxic
hazard had not been appreciated. On the other hand, risks tend to be controlled rou-
tinely with respect to compounds whose hazardous nature is well known, such as
ethylene oxide or nickel.
A flowchart in ISO 10993-18:2019 illustrates how chemical characterization data
drive the risk management process. The initial stage of the process, required in all
cases by ISO 10993-1:2018, is the gathering of physical and chemical information.
Combined with other available data addressing the biological endpoints relevant to the
device, this can be sufficient to estimate the risk. The risk estimate is a measure of the
likelihood and severity of harm arising as a result of exposure to a hazard that can give
rise to an adverse reaction during the interaction between the device and the body. The
term “biocompatible” corresponds to a region on the risk estimate scale where the risk
of an inappropriate biological response is negligible.
Annex B of ISO 10993-1:2018 itemizes this process as follows:
●
define and characterize each material, including suitable alternative materials;
●
identify hazards in materials, additives, processing aids, etc.;
●
identify the potential effect of downstream processing (e.g., chemical interactions between
material components, or final product sterilization) on chemicals present in final product;
●
identify the chemicals that could be released during product use (e.g., intermediate or final
degradation products from a degradable implant);
●
estimate exposure (total or clinically available amounts);
●
review toxicology and other biological safety data (published/available);
●
evaluate the risks posed by the identified hazards; and
●
determine whether there is an undue toxicological risk from the material.
The scope of this risk management process can be widened by considering perfor-
mance issues as potential hazards.
The final stage of the risk management process is the determination of risk accept-
ability. If a biological or performance-related risk is identified, it must be established
that it cannot be eliminated or reduced, for example by choosing another material or
process, and the residual risk must be outweighed by the benefit of the device. An im-
portant component of the risk estimate is the level of uncertainty in the risk analysis.
No biological evaluation can eliminate all unknowns so uncertainty always needs to
be factored into the residual risk estimate. Although the level of uncertainty is a crit-
ical factor in a biological evaluation, its impact on the overall risk assessment should
not be overplayed. The data simply need to be robust enough to allow the benefit-risk
balance to be established with confidence.
Part I of this book develops the above model and explores the challenges it throws
up in the planning and execution of a biological evaluation within a risk management
process. It shows that the use of a risk-based approach can justify an abbreviated eval-
uation program for clinically established materials, but novel, bioactive or biorespon-
sive materials need a more rigorous, bespoke investigation. As our expectations of
biomaterials and the claims we make of them become more demanding, we face new
challenges in testing and evaluation. This requires a carefully constructed biological
evaluation plan to define the information needed to characterize the risk.
xxForeword
The practical implications of the risk-based approach are developed in Part II, start-
ing with two chapters explaining how material characterization informs toxicological
risk assessment, moving on to a discussion of the various in vitro and in vivo tests that
are used to investigate the biological response to medical device materials and ending
with the identification of the key elements of decision-making in materials, processes
and the selection of new devices at the research and development or manufacturing
stages. Several chapters illustrate how to take account of specific requirements for
safety and performance based on the intended use of the device. Examples are given of
how a strategic, knowledge-led approach to planning a biological evaluation program
can build quality into design verification, reduce costs and timelines and increase the
evidential value of the results obtained.
In Part III, the description of the investigation and decision making process is
complemented by practical advice on strategies relevant to nonclinical performance
evaluation in specific device areas, such as drug-device combinations and orthopedic,
dental and soft tissue implants. Another section covers the role of histopathological
techniques in the evaluation of the biological response to medical devices, reflecting
the importance to biocompatibility and performance assessment of characterizing the
tissue response. Mechanical testing is also covered, to explore the impact of biome-
chanical forces on the performance of implants and the limitations of test results.
Safety and performance assessment is conducted within a regulatory context, and
the applicable regulations are themselves a form of risk management. With an under-
standing of the principles behind risk-based biological evaluation, readers will note
the extent to which they are reflected in regulatory processes in Europe, Japan and
China, which are described in Part IV.
This book describes many different types of data and it is important to consider
how each dataset contributes to the risk analysis, i.e., whether the data are used for
hazard identification or risk estimation, and whether there are any limitations inherent
in the test procedures or the way the data are used. For instance, most toxicity tests
were devised to determine whether a chemical compound is a toxicological hazard
and characterize any toxicity elicited. Hazard characterization tests can only be used
for risk estimation in conjunction with an exposure assessment. The use of tests with
device extracts in lieu of an exposure assessment is common practice, but it should be
recognized that this is an imprecise approximation that is not consistent with main-
stream toxicology. Extract-based tests typically lack the sensitivity of tests conducted
with pure compounds and cannot be relied upon to detect all hazards. The relative in-
sensitivity of extract-based tests needs to be taken into account when deciding whether
a test will provide a useful additional dataset, or when used to support a conclusion
that a risk is low.
For maximum effect, datasets providing information of direct relevance to the
endpoints identified in ISO 10993-1:2018 need to be considered in the context of an
evaluation that is in strict adherence to the risk management principles and process
defined by ISO 14971. This firstly involves the identification of hazards, based on
knowledge of device constituents and, where necessary, testing. Secondly, the risk
associated with exposure to each identified hazard is estimated, taking into account
the level of uncertainty in the risk analysis. Risk control measures, which may include
Forewordxxi
Dr Jeremy Tinkler
Introduction
No pain, no gain. That is what I learned soon after I started training for an ultra running
race. Today, the medical device industry is painfully progressing through multiple and
significant challenges, including: new technologies, new regulations, new interpreta-
tions of existing regulations, new geographic markets, industry consolidation, ongoing
globalization, key talent and cost limitations, and a need to sustain a faster pace to
bring new products to market.
Tantamount to athletes engaged in sport competition needing sound guidance,
medical device industry players need support to set up crystal clear differentiating
strategies and tactics that successfully and promptly make new technologies available
to patients. There is no room for uncertainties, planning, or execution errors.
As explained in the first edition, to accelerate market access, non-clinical safety
and performance evaluations play a key role in demonstrating that patients treated
with a new medical device are not placed at undue risk, and in providing reasonable
probability that new devices will offer the expected level of efficacy in human patients.
To succeed, multidisciplinary teams must collaborate to design, produce and ap-
prove non-clinical safety and performance studies that are ethical, scientifically sound
and compliant with applicable regulatory and quality standards. As illustrated by the
variety of backgrounds of contributors to this book, these teams include individu-
als with mechanical, chemical, material, biological, medical, quality and regulatory
backgrounds and experience from the medical device industry, contract research and
academic laboratories, notified bodies and governmental agencies.
To help you succeed with winning the race, it is my intention that this book offers
both strategic and practical advice to assist the reader in developing safe, effective
medical devices while shortening their developmental cycles.
1.1 Introduction
Medical devices (MDs) and biomaterials have been employed empirically for more
than 2000 years but their use has dramatically increased during the last century, essen-
tially over the last 40 years. In response to an ever-increasing demand for improved
quality of life in a steadily aging population, improved technologies in metal, ceramic
and polymer science have opened up new areas for MD applications in orthopedy,
cardiovascular assistance/repair, general surgery, and wound healing. It has been ac-
knowledged that in this rapidly evolving domain, the mean “industrial life” of a MD
is about five years.
Therefore, it is crucial that all stakeholders in the MD development process think
about how to bringing a product to market. Successful medical devices must speak to
all involved stakeholders. This simple yet vital concept is critically important when
considering medical device development and assessing the feasibility of device tech-
nology. Stakeholders in medical device innovation include the customer, marketing
specialists, the engineering and manufacturing team, safety/regulatory bodies, the
payer, and investors. Only through integrated development can truly safe and effective
MD be brought to market in a time and cost effective manner.
These stakeholders whom are jointly developing new concepts and products and
their challenge and that for the Regulatory Authorities is to ensure the safety and the
appropriate performance of MDs. Despite considerable progress in the development
of test standards for the evaluation of biological responses and notwithstanding a gen-
eral consensus about the efficacy of existing procedures, the predictive value of these
tests and their objectivity is still challenged. It is the aim of this chapter to report and
discuss how to think across the MD development process and offer critical examples
of the complex biocompatibility concepts.
Thus, early planning can save time and money by adding a few secondary data
endpoints to a clinical study rather than funding numerous post market studies. By
anticipating the needs of a diverse potential stakeholder population for a given device,
Strategies to accelerate medical market access and manage risks of biocompatibility5
companies can avoid developing products with limited value (or “low-value” prod-
ucts) and may avoid costly downstream data collection activities.
Biocompatibility is a key part of that. Increasingly raw material suppliers are keep-
ing their testing data on file with the FDA in a “Masterfile” that can include up to
permanent implant testing. While these materials won't be differentiating the time and
cost savings could be significant and reduce the need for biocompatibility testing from
6 mos to an 8 week chemical characterization and toxicology assessment.
●
The importance of interfacial phenomena as key factors of biocompatibility, for example,
the cellular macrophagic activation on material holes/ defects of 50 μm, the platelet and
hemostatic activation in contact with micro-defects in the range of 1–10 μm on the surface of
blood-contacting devices, the role of such micro-defects in the adhesion, the development of
microorganisms and biofilm formation, the encapsulation of smooth breast implants versus
texturized in addition to the well described specificities of chemical surface properties like
hydrophilicity/hydrophobicity, surface energy, etc.
These three components are summarized in Fig. 1.1, where the main characteristics
of MDs are summarized in the center, the safety issues are gathered on the left and