Non-union — the new bone never hardens.
Non-union and delayed union describe a regenerate that fails to consolidate on schedule. JOSR 2025 reports 5.1% delayed union pooled across methods. Internal-nail series (PRECICE) cluster at the low end (2–4%). External-fixator and hybrid series (LON, Ilizarov) cluster at 6–8%. Risk factors: smoking, distraction rate faster than 1 mm/day, weight-bearing too soon, low vitamin D, and patient age above 45.
Treatment is typically a revision surgery — bone grafting, dynamization of the nail, or external-fixator augmentation. Adds 3–6 months to the timeline.