Assessment of conformity of actual thoraco-lumbar pedicle screw dimensions to manufacturers' specifications.

Although correct selection of pedicle screw dimensions is indispensable to achieving optimum results, manufacturer-specified or intended dimensions may differ from actual dimensions. Here we analyzed the reliability of specifications made by various manufacturers by comparing them to the actual lengths and diameters of pedicle screws in a standardized experimental setup. We analyzed the actual length and diameter of pedicle screws of five different manufacturers. Four different screw lengths and for each length two different diameters were measured. Measurements were performed with the pedicle screws attached to a rod, with the length determined from the bottom of the tulip to the tip of the screw and the diameters determined at the proximal and distal threads. Differences in length of > 1 mm were found between the manufacturers' specifications and our actual measurements in 24 different pedicle screws. The highest deviation of the measured length from the manufacturers' specification was 3.2 mm. The difference in length between the shortest and longest screw with identical specifications was 3.4 mm. The highest deviation of the measured proximal thread diameters and the manufacturer's specifications was 0.5 mm. The diameter of the distal thread depends on the shape of the pedicle screw and hence varies between manufacturers in conical screws. We found clear differences in the length of pedicle screws with identical manufacturer specifications. Since differences between the actual dimensions and the dimensions indicated by the manufacturer may vary, this needs to be taken into account during the planning of spine instrumentation.