Toon Lambrechts

Large-scale progenitor cell expansion for multiple donors in a monitored hollow fibre bioreactor

BACKGROUND AIMS With the increasing scale in stem cell production, a robust and controlled cell expansion process becomes essential for the clinical application of cell-based therapies. The objective of this work was the assessment of a hollow fiber bioreactor (Quantum Cell Expansion System from Terumo BCT) as a cell production unit for the clinical-scale production of human periosteum derived stem cells (hPDCs). METHODS We aimed to demonstrate comparability of bioreactor production to standard culture flask production based on a product characterization in line with the International Society of Cell Therapy in vitro benchmarks and supplemented with a compelling quantitative in vivo bone-forming potency assay. Multiple process read-outs were implemented to track process performance and deal with donor-to-donor-related variation in nutrient needs and harvest timing. RESULTS The data show that the hollow fiber bioreactor is capable of robustly expanding autologous hPDCs on a clinical scale (yield between 316 million and 444 million cells starting from 20 million after ± 8 days of culture) while maintaining their in vitro quality attributes compared with the standard flask-based culture. The in vivo bone-forming assay on average resulted in 10.3 ± 3.7% and 11.0 ± 3.8% newly formed bone for the bioreactor and standard culture flask respectively. The analysis showed that the Quantum system provides a reproducible cell expansion process in terms of yields and culture conditions for multiple donors.

Model-based cell number quantification using online single-oxygen sensor data for tissue engineering perfusion bioreactors †

Online and non‐invasive quantification of critical tissue engineering (TE) construct quality attributes in TE bioreactors is indispensable for the cost‐effective up‐scaling and automation of cellular construct manufacturing. However, appropriate monitoring techniques for cellular constructs in bioreactors are still lacking. This study presents a generic and robust approach to determine cell number and metabolic activity of cell‐based TE constructs in perfusion bioreactors based on single oxygen sensor data in dynamic perfusion conditions. A data‐based mechanistic modeling technique was used that is able to correlate the number of cells within the scaffold (R2 = 0.80) and the metabolic activity of the cells (R2 = 0.82) to the dynamics of the oxygen response to step changes in the perfusion rate. This generic non‐destructive measurement technique is effective for a large range of cells, from as low as 1.0 × 105 cells to potentially multiple millions of cells, and can open‐up new possibilities for effective bioprocess monitoring. Biotechnol. Bioeng. 2014;111: 1982–1992.

Large-Scale Mesenchymal Stem/Stromal Cell Expansion: A Visualization Tool for Bioprocess Comparison.

Large-scale and cost-effective cell expansion processes are a prerequisite for the clinical and commercial translation of cell-based therapies. A large variety of cell expansion processes are described in literature, utilizing different cell types, culture vessels, and medium formulations. Consequently there are no straightforward means for the comparison or benchmarking of these processes in terms of efficiency, scale, or costs. The purpose of this study was to systematically review the available mesenchymal stromal cell (MSC) expansion literature and develop an interactive visualization tool for comparing the expansion processes. By using this computational tool, process data could be concentrated, standardized, and analyzed to facilitate a more general understanding of the parameters that define a cell culture process, and in the future allow rational selection or design of these bioprocesses. Additionally, a set of bioprocess metrics were defined that assured the comparability between different processes. Currently, the literature-based data repository holds 73 individual cell expansion processes on seven different types of human MSCs in five different types of culture vessels. The visualization tool allowed benchmarking of these processes against each other, serving as a reference point for cell expansion process efficiency.

Product and Process Design: Toward Industrial TE Manufacturing

Abstract As the field of tissue engineering matures and the transition from bench-scale to large-scale industrialized production is realized, a new set of biological and technological challenges arises. To bring tissue-engineered products to the clinic and subsequently to the market will require the application of engineering principles and practices to achieve control, reproducibility, automation, validation, and safety of the process and the product. The successful translation will require contributions not only from fundamental research (from developmental biology to advanced modeling mathematical approaches) but also from existing industrial practice (biopharma), especially on automation, quality assurance, and regulation.

High-throughput image-based monitoring of cell aggregation and microspheroid formation

Studies on monolayer cultures and whole-animal models for the prediction of the response of native human tissue are associated with limitations. Therefore, more and more laboratories are tending towards multicellular spheroids grown in vitro as a model of native tissues. In addition, they are increasingly used in a wide range of biofabrication methodologies. These 3D microspheroids are generated through a self-assembly process that is still poorly characterised, called cellular aggregation. Here, a system is proposed for the automated, non-invasive and high throughput monitoring of the morphological changes during cell aggregation. Microwell patterned inserts were used for spheroid formation while an automated microscope with 4x bright-field objective captured the morphological changes during this process. Subsequently, the acquired time-lapse images were automatically segmented and several morphological features such as minor axis length, major axis length, roundness, area, perimeter and circularity were extracted for each spheroid. The method was quantitatively validated with respect to manual segmentation on four sets of ± 60 spheroids. The average sensitivities and precisions of the proposed segmentation method ranged from 96.67–97.84% and 96.77–97.73%, respectively. In addition, the different morphological features were validated, obtaining average relative errors between 0.78–4.50%. On average, a spheroid was processed 73 times faster than a human operator. As opposed to existing algorithms, our methodology was not only able to automatically monitor compact spheroids but also the aggregation process of individual spheroids, and this in an accurate and high-throughput manner. In total, the aggregation behaviour of more than 700 individual spheroids was monitored over a duration of 16 hours with a time interval of 5 minutes, and this could be increased up to 48,000 for the described culture format. In conclusion, the proposed system has the potential to be used for unravelling the mechanisms involved in spheroid formation and monitoring their formation during large-scale manufacturing protocols.