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For drug discovery, new in vitro cancer models are needed to obtain more translatable study outcomes in a low-cost and high-throughput manner. For this purpose, 3D cancer spheroids have been established as more effective than 2D models. Current commercial techniques, however, rely heavily on self-aggregation of dissociated cells and cannot replicate key features of the native tumor microenvironment, particularly due to a lack of control over extracellular matrix components and heterogeneity in size and aggregate-forming tendencies. Also, current spheroidal techniques are typically limited to one spheroid per well, therefore providing a narrow range of cell numbers per well, disadvantageous for assay development in drug screening. Here, we overcome these challenges by coupling tissue engineering toolsets with microfluidic technologies to create engineered cancer microspheres and sorting desired numbers of microspheres into assay-ready well-plate format. To form the engineered cancer microspheres, MCF7 (non-metastatic) and MDA-MB-231 (metastatic) breast cancer cells were encapsulated within poly(ethylene glycol)-fibrinogen hydrogels using our previously developed microfluidic platform. Highly uniform cancer microspheres (intra and inter-batch coefficient of variation ≤ 5%) with high cell densities (over 20 × 106 cells/ml) were produced rapidly, which is critical for use in drug testing. The microspheres supported the 3D culture of both breast cancer cell lines over at least 14 days in culture. Encapsulated cells displayed cell type-specific differences in morphology, proliferation, metabolic activity, ultrastructure, and overall microsphere size distribution and bulk stiffness. To prepare assay-ready pre-plated microspheres, a COPAS FP flow cytometer was used for its ability to analyze and sort large sample particles such as tumor spheroids and hydrogel cancer microspheres generated in this study. When using a 96-well plate, the sorting rate varied from 2.5 - 6 microspheres per second, depending on the sample concentration. When sorting a desired number of microspheres per well, the accuracy was greater than 95% as verified visually by microscopy. Viability of sorted microspheres was verified 24 hours post-sort. Shipping conditions were established that maintained cell viability for remote use in drug testing. Methods for compound addition by pinning and imaging were tested and optimized. Using these approaches, the microsphere system was shown to be compatible with an automated liquid handling system for administration of drug compounds; MDA-MB-231 microspheres were distributed in 384 well plates and treated with chemotherapeutic drugs. Expected responses were quantitated using CellTiter-Glo® 3D and detected using automated imaging. Overall, our results demonstrate initial applicability for the tissue-engineered cancer microspheres for drug screening. 

Abstract There is a need for new in vitro systems that enable pharmaceutical companies to collect more physiologically-relevant information on drug response in a low-cost and high-throughput manner. For this purpose, three-dimensional (3D) spheroidal models have been established as more effective than two-dimensional models. Current commercial techniques, however, rely heavily on self-aggregation of dissociated cells and are unable to replicate key features of the native tumor microenvironment, particularly due to a lack of control over extracellular matrix components and heterogeneity in shape, size, and aggregate forming tendencies. In this study, we overcome these challenges by coupling tissue engineering toolsets with microfluidics technologies to create engineered cancer microspheres. Specifically, we employ biosynthetic hydrogels composed of conjugated poly(ethylene glycol) (PEG) and fibrinogen protein (PEG-Fb) to create engineered breast and colorectal cancer tissue microspheres for 3D culture, tumorigenic characterization, and examination of potential for high-throughput screening (HTS). MCF7 and MDA-MB-231 cell lines were used to create breast cancer microspheres and the HT29 cell line and cells from a stage II patient-derived xenograft (PDX) were encapsulated to produce colorectal cancer (CRC) microspheres. Using our previously developed microfluidic system, highly uniform cancer microspheres (intra-batch coefficient of variation (CV) ≤ 5%, inter-batch CV < 2%) with high cell densities (>20×106 cells/ml) were produced rapidly, which is critical for use in drug testing. Encapsulated cells maintained high viability and displayed cell type-specific differences in morphology, proliferation, metabolic activity, ultrastructure, and overall microsphere size distribution and bulk stiffness. For PDX CRC microspheres, the percentage of human (70%) and CRC (30%) cells was maintained over time and similar to the original PDX tumor, and the mechanical stiffness also exhibited a similar order of magnitude (103 Pa) to the original tumor. The cancer microsphere system was shown to be compatible with an automated liquid handling system for administration of drug compounds; MDA-MB-231 microspheres were distributed in 384 well plates and treated with staurosporine (1 μM) and doxorubicin (10 μM). Expected responses were quantified using CellTiter-Glo® 3D, demonstrating initial applicability to HTS drug discovery. PDX CRC microspheres were treated with Fluorouracil (5FU) (10 to 500 μM) and displayed a decreasing trend in metabolic activity with increasing drug concentration. Providing a more physiologically relevant tumor microenvironment in a high-throughput and low-cost manner, the PF hydrogel-based cancer microspheres could potentially improve the translational success of drug candidates by providing more accurate in vitro prediction of in vivo drug efficacy. Citation Format: Elizabeth A. Lipke, Wen J. Seeto, Yuan Tian, Mohammadjafar Hashemi, Iman Hassani, Benjamin Anbiah, Nicole L. Habbit, Michael W. Greene, Dmitriy Minond, Shantanu Pradhan. Production of cancer tissue-engineered microspheres for high-throughput screening [abstract]. In: Proceedings of the American Association for Cancer Research Annual Meeting 2022; 2022 Apr 8-13. Philadelphia (PA): AACR; Cancer Res 2022;82(12_Suppl):Abstract nr 175. 

The role of hydrogel properties in regulating the phenotype of triple negative metastatic breast cancer is investigated using four cell lines: the MDA‐MB‐231 parental line and three organotropic sublines BoM‐1833 (bone‐tropic), LM2‐4175 (lung‐tropic), and BrM2a‐831 (brain‐tropic). Each line is encapsulated and cultured for 15 days in three poly(ethylene glycol) (PEG)‐based hydrogel formulations composed of proteolytically degradable PEG, integrin‐ligating RGDS, and the non‐degradable crosslinker N‐vinyl pyrrolidone. Dormancy‐associated metrics including viable cell density, proliferation, metabolism, apoptosis, chemoresistance, phosphorylated‐ERK and ‐p38, and morphological characteristics are quantified. A multimetric classification approach is implemented to categorize each hydrogel‐induced phenotype as: 1) growth, 2) balanced tumor dormancy, 3) balanced cellular dormancy, or 4) restricted survival, cellular dormancy. Hydrogels with high adhesivity and degradability promote growth. Hydrogels with no adhesivity, but high degradability, induce restricted survival, cellular dormancy in the parental line and balanced cellular dormancy in the organotropic lines. Hydrogels with reduced adhesivity and degradability induce balanced cellular dormancy in the parental and lung‐tropic lines and balanced tumor mass dormancy in bone‐ and brain‐tropic lines. The ability to induce escape from dormancy via dynamic incorporation of RGDS is also presented. These results demonstrate that ECM properties and organ‐tropism synergistically regulate cancer cell phenotype and dormancy.

 

This study establishes a novel microfluidic platform for rapid encapsulation of cells at high densities in photocrosslinkable microspherical hydrogels including poly(ethylene glycol)‐diacrylate, poly(ethylene glycol)‐fibrinogen, and gelatin methacrylate. Cell‐laden hydrogel microspheres are advantageous for many applications from drug screening to regenerative medicine. Employing microfluidic systems is considered the most efficient method for scale‐up production of uniform microspheres. However, existing platforms have been constrained by traditional microfabrication techniques for device fabrication, restricting microsphere diameter to below 200 µm and making iterative design changes time‐consuming and costly. Using a new molding technique, the microfluidic device employs a modified T‐junction design with readily adjustable channel sizes, enabling production of highly uniform microspheres with cell densities (10–60 million cells mL⁻¹) and a wide range of diameters (300–1100 µm), which are critical for realizing downstream applications, through rapid photocrosslinking (≈1 s per microsphere). Multiple cell types are encapsulated at rates of up to 1 million cells per min, are evenly distributed throughout the microspheres, and maintain high viability and appropriate cellular activities in long‐term culture. This microfluidic encapsulation platform is a valuable and readily adoptable tool for numerous applications, including supporting injectable cell therapy, bioreactor‐based cell expansion and differentiation, and high throughput tissue sphere‐based drug testing assays.