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One-stop microfiber spinning and fabrication of a fibrous cell-encapsulated


scaffold on a single microfluidic platform

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DOI: 10.1088/1758-5082/6/2/024108

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Biofabrication
Biofabrication 6 (2014) 024108 (7pp) doi:10.1088/1758-5082/6/2/024108

One-stop microfiber spinning and


fabrication of a fibrous cell-encapsulated
scaffold on a single microfluidic platform
D Y Park 1,3 , C H Mun 1,3 , E Kang 1 , D Y No 1 , J Ju 1 and S H Lee 1,2,4
1
Department of Biomedical Engineering, College of Health Science, Korea University, Seoul 136-703,
Korea
2
KU-KIST Graduate School of Converging of Sciences & Technologies, Korea University,
Seoul 136-713, Korea
E-mail: dbiomed@korea.ac.kr

Received 28 May 2013, revised 16 October 2013


Accepted for publication 31 October 2013
Published 10 April 2014

Abstract
This paper provides a method for microscale fiber spinning and the in situ construction of a 3D
fibrous scaffold on a single microfluidic platform. This platform was also used to fabricate a
variety of fibrous scaffolds with diverse compositions without the use of complicated devices.
We explored the potential utility of the fibrous scaffolds for tissue engineering applications by
constructing a fibrous scaffold encapsulating primary hepatocytes. The cells in scaffold were
cultured over seven days and maintained higher viability comparing with 3D alginate
non-fibrous block. The main advantage of this platform is that the fibrous structure used to
form a scaffold can be generated without damaging the mechanically weak alginate fibers or
encapsulated cells because all procedures are performed in a single platform without the
intervention of the operator. In addition, the proposed fibrous scaffold permitted high diffusion
capability of molecules, which enabled better viability of encapsulated cells than non-fibrous
scaffold even in massive cell culture.

Keywords: microfluidic, 3D alginate fibrous scaffold, cell-laden fibers, porosity

S Online supplementary data available from stacks.iop.org/BF/6/024108/mmedia


(Some figures may appear in colour only in the online journal)

1. Introduction bio-degradable with an appropriate degradation time, and


they should maintain their mechanical integrity over a pre-
In the human body, the extracellular matrix (ECM) plays a key determined timeframe [2–7]. To date, numerous studies have
role in positioning cells for tissue regeneration, temporarily attempted to produce scaffolds that satisfy these requirements
substituting tissue functions, guiding tissue ingrowth and by employing methods that involve particulate leaching
maintaining the overall tissue functions [1]. Scaffolds used [8, 9], gas foaming [10], micro- and nano-fiber networking
for tissue engineering should resemble the structural and [11, 12], solution casting [13], microstereolithography
chemical properties of the target tissue’s ECM as closely as [14], rapid prototyping [15–17] and combinations of these
possible, and should include high porosity for nutrient/waste techniques. Among these methods, fiber-based scaffold
flow and tissue ingrowth, appropriate structural geometries fabrication has attracted much attention due to its advantages
and pore dimensions. In addition, the scaffolds should be in the context of guided cell growth, cell networking and for
the ability to control the porosity. Recent progress in electro-
3 These authors contributed equally to this study. spinning technologies has led to the development of nanofibers
4 Author to whom any correspondence should be addressed. with a diversity of shapes and sizes. These nanofibers have

1758-5082/14/024108+07$33.00 1 © 2014 IOP Publishing Ltd Printed in the UK


Biofabrication 6 (2014) 024108 D Y Park et al

been broadly used as biomimetic scaffolds because they Onto the top and middle layers, cylindrical channel patterns
can provide networked structures similar to collagen [18]. were engraved to generate a coaxial flow, whereas the bottom
Although nanofiber scaffolds have contributed much to our layer included a nylon mesh filter (mesh size 70 μm, BD
understanding of cell–ECM interactions, thereby advancing Falcon). The filter was integrated into the PDMS chip after
tissue engineering applications, nanofiber scaffolds are limited cutting the filter with scissors into square-shaped pieces
in their practical utility because they are only fabricated about 10 mm wide. A piece of the filter was aligned and
using two-dimensional platforms. We and other researchers bonded to the accumulating chamber of the middle layer
have developed a new spinning method that overcomes this using a PDMS prepolymer as glue. The scanning electron
limitation by the continuous spinning of microscale fibers microscopy (FE-SEM, JEOL) image in figure 1(a) shows
using a microfluidic chip [19–24]. This spinning method is a magnified view of the filter structure. The microfluidic
advantageous in providing spatiotemporal control over the chip was constructed by bonding layers via oxygen plasma
composite material composition, size and morphology, and treatment (CUTE-MP, FEMTO SCIENCE). Into the inlet of
encapsulation of cells; however, the use of these fibers as three- the sheath and sample channels, the sample fluid (collagen-
dimensional (3D) scaffolds requires the development of new alginate solution) and sheath fluid (3% (w/v) calcium chloride,
processes and devices. Previous methods used an acryl spool Sigma) were introduced respectively, and the flow speed of
to wind a microfiber and construct a pseudo 3D structure [25]. each fluid was controlled using a syringe pump (KDS-100,
Although the winding method is advantageous in assembling KD Scientific). Collagen-alginate solution was prepared as
aligned 3D structures, microfiber winding requires skill, is previously described [29]. The sheath flow not only prevented
labor-intensive and is a fragile process requiring much care. contact between the sample flow and the channel wall, but
Here, we describe a microfluidic spinning PDMS chip that also it shaped the focused sample flow and induced gelation of
is integrated with a 3D fibrous scaffold fabrication chamber alginate via Ca2+ ion chelation to form a solid microfiber. The
on a single microfluidic platform for the one-stop construction gelled fibers were extruded from the end of the outlet channel
of a fibrous scaffold. We made a single microfluidic platform and collected into the accumulating chamber, and the venting
system for fibrous cell-laden scaffolds that can easily control channel was opened to retrieve the lumped fibers only. The
the shape and volume of cell-laden alginate scaffold and process is summarized in detail in figure 1(b). To show the
porosity. Recently, the cell-laden fibrous scaffold has attracted spatial coding of fiber with different materials, Janus fibers
great attention due to its extensive applications [26]. However, were fabricated by preparing a microfluidic spinning chip
the handling and shape formation of cell-laden alginate consisting of multiple sample inlets (see figure S1(a), available
at stacks.iop.org/BF/6/024108/mmedia). The simultaneous
fiber is challenging due to its mechanical weakness. In
introduction of alginate solutions containing different types
addition, the microfluidic device could reduce the possibility
of nano particles yielded double- or triple-layer Janus fibers.
of contamination, cost and labor. Microfluidic spinning was
In addition, by the integration of multiple spinning channels,
accomplished using a cylindrical channel to generate a coaxial
we fabricated the complex fibrous scaffold consisting of fibers
sheath and sample flow [27, 28]. The resulting fibers were
with different compositions as shown in figure S1(b) (available
collected in an accumulation chamber fabricated at the outlet
at stacks.iop.org/BF/6/024108/mmedia).
of the spinning channel, and a buffer solution was pumped
into the bottom of the chamber through a filter that separated
the fibers from the solution. The performance of scaffold was 2.2. Porosity control of the fibrous scaffold
evaluated by measuring the porosity of the scaffolds prepared The porosity of a fibrous scaffold can be easily controlled
under different flow rates. We also fabricated a scaffold using according to the flow rates of both the sample and sheath fluids.
diverse fibers with different compositions to demonstrate the This relationship was explored by calculating the porosity of
capabilities with respect to ECM property modulation. the fibrous scaffold based on the volume percentage of fibers
The functionality of the scaffold was briefly demonstrated in the accumulating chamber, and the porosity was determined
by encapsulating primary hepatocytes from a rat within a as follows:
fiber during the spinning process, and the cell viability was Qsample × T
evaluated. The proposed method permitted control over the Porosity = 1 − ,
t × Achamber
dimensions of the scaffold, even when many materials were where Qsample is the sample flow rate, T is the fiber spinning
used to fabricate the microfibers, suggesting that the method is time, t is the scaffold thickness and Achamber is the accumulating
promising for future tissue engineering applications requiring chamber area. The scaffold thickness was measured using a
careful control over the dimensions and compositions of the confocal microscope, and the sample flow rate was set to 3,
scaffold. 5 or 7 μL min−1, and the sheath flow rate was set to 20 or
30 mL h−1. The dependence of the resulting porosity on the
2. Materials and methods respective flow rates could, therefore, be determined.

2.1. Method design, spinning process, and collecting chip 2.3. Calculation of the diffusion characteristics through the
fibrous scaffolds
We designed and fabricated a microfluidic chip for the one-
stop construction of a fibrous scaffold. The chip consisted Fibrous scaffolds are broadly useful in tissue engineering
of three layers: top, middle and bottom layers (figure 1(a)). applications; for example, they can be used to encapsulate

2
Biofabrication 6 (2014) 024108 D Y Park et al

(a)

(b)

Figure 1. Production of the fibrous scaffold. (a) Schematic diagram of the microfluidic chip used to fabricate the fibrous scaffolds (the inset
shows a magnified SEM image of the filter). (b) Detailed schematic diagram showing the fibrous scaffold generation process: (bottom, left)
the spinning duct, (bottom, middle) gelation of the sample fluid in a cylindrical channel and (bottom, right) fibrous scaffold construction in
the accumulating chamber. The scale bar indicates 70 μm in (a).

or to seed cells, to guide cell growth and to deliver embedded 2.4. Isolation of primary rat hepatocytes
bioactive materials. The transportation of molecules through
the fiber scaffold is important in these applications. Here, we Primary hepatocytes were isolated from 8-week-old male
simulated molecular transport through a single fiber using Sprague-Dawley rats (DBL, Seoul, South Korea), weighing
the finite element method software (COMSOL). A steady- 250–280 g, using a two-step collagenase perfusion procedure,
state solution to the convection and diffusion modules was as previously described [31–33]. Primary hepatocytes were
established to investigate the concentration of the sample cultured in the high-glucose Dulbecco’s modified eagle’s
molecule at each point in the fiber. Glucose (molecule weight: medium (DMEM, GIBCO) supplemented with 20 mM
180.16 g mol−1) was modeled as the sample molecule in
HEPES, 25 mm NaHCO3, 30 mg L−1 proline, 10% fetal
these calculations because glucose is a typical nutrient and
bovine serum (FBS, GIBCO), 25 U mL−1 penicillin,
is generally required by all cell types. The initial glucose
concentration at the boundary was set to 5.56 mol m−3, and 25 μg mL−1 streptomycin, 10 μg mL−1 gentamicin,
the diffusion coefficient characterizing the transport of glucose 10 ng mL−1 epidermal growth factor (EGF, GIBCO),
to the alginate domain was set to 6.8 × 10−6 m2 s−1 [30]. 50 ng mL−1 insulin, 10−4 m dexamethasone, 10 mm
Molecular transport was quantified by measuring the glucose nicotinamide, and 100 mm L-ascorbic acid. All procedures
concentration change at the center of the fiber over time. adhered to the guidelines of the IRB of Korea University.

3
Biofabrication 6 (2014) 024108 D Y Park et al

(a) (b)

(c) (d ) (e)

Figure 2. Fluorescence images of the fibrous scaffolds. (a) Fluorescence image of an alginate fiber in a spinning duct. (b) Merged confocal
images of the fibrous scaffold. (c)–(e) Confocal images of multi-component fibers prepared with (c) one sample, (d) two samples or (e) three
samples. The scale bars indicate 200 μm in (a), 1 mm in (b), 100 μm in (c)–(e) (upper) and 400 μm in (c)–(e) (lower).

2.5. Fabrication of a fibrous scaffold using accumulating chamber boundary. The Janus chip was used to
hepatocyte-embedded fibers and viability test fabricate diverse fibers having spatially different compositions
in large quantities, as shown in the 3D confocal image in
Hepatocytes were encapsulated in the fibers using a
figures 2(c)–(e). The inset of each figure shows a schematic
microfluidic chip described previously [34]. We dispersed the
diagram of the cross-sectional view. The characteristics of the
prepared hepatocytes in a 2% (w/v) alginate solution at a
concentration of 5 × 106 cells mL−1. The solution containing fibrous scaffold, including the scaffold thickness growth rate
hepatocytes was introduced through the sample channel at and porosity, were quantitatively measured as a function of the
an average flow rate of 90 μL min−1. After channel closure, flow rate.
we removed the cylindrical spinning channel by cutting with Figure 3(a) shows a 3D confocal image of the fibrous
a scalpel blade, and the accumulating chamber, including scaffold. Z-plane images of the fibrous scaffold were collected
the fibrous scaffold, was transferred to the cell culture dish from 0 to 2 mm in steps of 0.1 mm using confocal microscopy,
containing primary hepatocyte culture medium to maintain the and a stacked image was reconstructed. The thickness of
3D scaffold shape. The cells and scaffold were co-incubated the scaffold was assessed from the side view of the image
in an incubator over the next seven days, and the cell viability (figure 3(a), XZ projection). Porosity was calculated using the
was assessed by adding 50 mM Calcein-AM and 25 mg mL−1 equation given above. As shown in figure 3(b), the porosity of
ethidium homodimer-1 (EthD-1; Molecular Probes, USA) to the scaffold could be controlled simply by changing the flow
the culture medium and by incubating for 40 min at 37 ◦ C. rate (both the sample and sheath flow rates), yielding porosity
values between 0.23 and 0.52. By connecting the outlets of
3. Results three separate spinning channels to a single accumulating
chamber, we produced complex fibrous scaffolds in which
Figure 2(a) shows the dyed alginate sample flow traveling three fibers with different compositions were spatially mixed
through a cylindrical channel in the PDMS, followed by the (figure 3(c)). Figures 3(d) and (e) show, respectively, 3D and
focusing of the sample flow by the CaCl2 sheath flow. The 2D confocal images of the complex fibrous scaffold. We
gelled and extruded fibers were collected in the accumulating fabricated cell-laden fibers which were composed with rat
chamber over 7–8 min, as shown in figure 2(b) (the buffer primary islet cells and adipose stem cells (figure S4, available
solution was vented). The white dotted circle indicates the at stacks.iop.org/BF/6/024108/mmedia).

4
Biofabrication 6 (2014) 024108 D Y Park et al

(a) (b)
at stacks.iop.org/BF/6/024108/mmedia) shows the resulting
image of Live/Dead assay performed on cells encapsulated
in the fibrous scaffold on day 7 after the cell seeding,
respectively. The green and red colors represent live and
dead cells, respectively. The cell viability on the fibrous
scaffold was compared with the values on the three-
dimensional culture in alginate blocks with the same volume.
Cells encapsulated in the fibrous scaffold survived more
than cells cultured in 3D alginate block (figure S3 and
S4, available at stacks.iop.org/BF/6/024108/mmedia), as
(c) (d ) (e) expected. Cells in the fibrous scaffolds showed a much
higher viability during whole culture day than 3D alginate
bulk scaffold culture conditions (figure S5, available at
stacks.iop.org/BF/6/024108/mmedia).

4. Discussion

A one-stop microfiber spinning and fabrication device for


Figure 3. Characteristics of the fibrous scaffold. (a) Confocal producing fibrous scaffolds was successfully constructed.
Z-stack images obtained during three-dimensional imaging of the
fibrous scaffold. (b) Porosity of the fibrous scaffold as a function of The fiber accumulating chamber, outfitted with a 70 μm
the flow rate. (c) Schematic diagram showing the fabrication of a mashed filter that vented the buffer solution away from
complex fibrous scaffold. Confocal images of a complex fibrous the fiber, collected the fibrous scaffold structure without
scaffold in (d) three dimensions and (e) two dimensions. The scale the need for additional processes or devices. All processes
bars indicate 400 μm in (a) and 1 mm in (d). were performed on a single microfluidic platform without
the intervention of the operator. The mechanical strength of
Glucose transport was modeled as described above. The alginate microfibers is weak, which complicates fiber handling
simulation results shown in figure 4(a) reveal that a fiber with during the construction of 3D structures; however, as the
a diameter of 100 μm rapidly transported nutrients (glucose) proposed platform enabled all fabrication processes to be
into the inside of the fiber. Exposure of the fiber to glucose performed on a single platform, the mechanical weakness of
increased the glucose concentration at the center of the fiber the fiber was not problematic at all. The accumulated fiber was
from 0 to 5.409 mol m−3 within 10 s (figure 4(b)). We cultured distributed uniformly in the chamber, and it aggregates to form
rat primary hepatocytes three-dimensionally with two types of a lump like a skein upon drying. The growth rate of the scaffold
culture methods: three-dimensional culture in alginate block thickness was not affected by the flow rate. The porosity of
and in fibrous scaffolds. the scaffold, on the other hand, could be regulated by varying
The cell densities in the alginate blocks and the the flow rate. By decreasing the sample flow rate, the fiber
fibrous scaffolds were identical, 5 × 106 cells mL−1, diameter could be reduced and the porosity of the fibrous
and the volume of alginate blocks and whole fibrous scaffold could be decreased. A scaffold consisting of a dense
scaffolds is almost identical too. Figure S3 (available fibrous structure formed by small-diameter fibers was thereby

(a) (b)

(c) (d )

Figure 4. Glucose diffusion simulation results in the alginate fibrous scaffold and alginate bulk scaffold. (a) Changes in the glucose
concentration across the single alginate fiber, (b) plot of the concentration at the center of the single alginate fiber as a function of time, (c)
changes of glucose concentration in 3D alginate bulk scaffold. Glucose concentration at boundary was set to 5.56 mol m−3. (d) Plot of
concentration at different points (A), (B) and (C) versus time.

5
Biofabrication 6 (2014) 024108 D Y Park et al

formed. An increase in the number of spinning channels porosity of the scaffold could be readily controlled by varying
and the introduction of different materials into each channel the fluid flow rates. The porosity of fibrous scaffold was
permitted the construction of complex scaffolds composed high compared to the porosity of a bulk hydrogel scaffold,
of diverse materials. Each different fiber was distributed and these scaffolds are advantageous for easy diffusion of
uniformly throughout the scaffold. Scaffolds generally require nutrient, oxygen and other molecules to the encapsulated cells
materials that promote cell interactions, adhesion, proliferation in fiber. All processes were performed in situ on a single
and migration. The bioactivity of our fibrous scaffold may platform, which avoided damaging the weak cell-laden fibers
be controlled by incorporating growth factors, enzymatic and facilitated the easy handling and shape forming of cell-
recognition sites and adhesion factors into each fiber. The laden fibers. If prepared using fibers with diverse cells or
fiber itself may be spatiotemporally coded along the fiber axis materials, the fibrous scaffold may potentially be used to mimic
by introducing different sample compositions over time, as the partial support or regeneration of an organ or tissue.
reported previously [20]. Modifications to the scaffold on
the microscale or in bulk can, therefore, be achieved. As Acknowledgments
shown in this study, cells may be immobilized within the
fibers, and the proposed technology could potentially support This work was supported by the National Research Foundation
tissue engineering applications that involve diverse cells. The of Korea (NRF), funded by the Korean Government (MEST)
cell-based study definitively demonstrates the advantages of (no. 201304640). Support was also provided by the Industrial
the proposed fibrous scaffold. According to figure S3 and Core Technology Development Program (no. 10041923),
figure S4 (available at stacks.iop.org/BF/6/024108/mmedia), funded by the Ministry of Knowledge Economy. This work was
hepatocytes in the alginate block showed lower viability also supported by Seoul R&BD program (grant no. SS110011)
than in the fibrous scaffold at the seventh day, possibly
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