Oxygen transport and cell viability in an annular flow bioreactor: comparison of laminar Couette and Taylor-vortex flow regimes

Rotating wall vessel bioreactors have been proposed as a means of controlling the fluid dynamic environment during long-term culture of mammalian cells and engineered tissues. In this study, we show how the delivery of oxygen to cells in an annular flow bioreactor is enhanced by the forced convective transport afforded by Taylor vortex flows. A fiberoptic oxygen probe with negligible lag time was used to measure the dissolved oxygen concentration in real time and under carefully controlled aeration conditions. From these data, the overall mass transfer coefficients were calculated and mass transport correlations determined under laminar Couette flow conditions and discrete Taylor vortex flow regimes, including laminar, wavy, and turbulent flows. While oxygen transport in Taylor vortex flows was significantly greater, and the available oxygen exceeded that consumed by murine fibroblasts in free suspension, the proportion of cells that remained viable decreased with increasing Reynolds number (101.8 < Rei < 1018), which we attribute to the action of fluid shear stresses on the cells as opposed to any limitation in mass transport. Nevertheless, the results of this study suggest that laminar Taylor-vortex flow regimes provide an effective means of maintaining the levels of oxygen transport required for long-term cell culture.     

A viscous pump bioreactor

The fluid dynamic design and characterization of a low mechanical stress agitator and bioreactor vessel for large-scale bioprocessing using anchorage dependent mammalian cells is considered. The complex and fragile nature of mammalian cells puts stringent constraints on the design of agitators for stirred tank bioreactors. Traditional agitators have difficulty meeting the competing requirements of fluidization and mixing while maintaining low enough mechanical stress levels to avoid cell damage. A rotating disc agitator design is proposed. Flow visualization and laser Doppler velocimeter measurements reveal fluidization of microcarriers with a gentle (low turbulence level), highly three-dimensional flow characterized by good mixing at low hydrodynamic shear stress levels.     

Mechanobiology of engineered cartilage cultured under a quantified fluid-dynamic environment

Natural cartilage remodels both in vivo and in vitro in response to mechanical forces and hence mechanical stimulation is believed to have a potential as a tool to modulate extra-cellular matrix synthesis in tissue-engineered cartilage. Fluid-induced shear is known to enhance chondrogenesis on animal cells. A well-defined hydrodynamic environment is required to study the biochemical response to shear of three-dimensional engineered cell systems. We have developed a perfused-column bioreactor in which the culture medium flows through chondrocyte-seeded porous scaffolds, together with a computational fluid-dynamic model of the flow through the constructs' microstructure. A preliminary experiment of human chondrocyte growth under static versus dynamic conditions is described. The median shear stress imposed on the cells in the bioreactor culture, as predicted by the CFD model, is 3 × 10⁻³ Pa (0.03 dyn/cm²) at a flow rate of 0.5 ml/min corresponding to an inlet fluid velocity of 44.2 μm/s. Providing a fluid-dynamic environment to the cells yielded significant differences in cell morphology and in construct structure. Received: 22 December 2001 / Accepted: 18 February 2002     

可控多孔结构支架制备及灌注式体外培养

利用CAD和快速成形技术设计制造具有可控多孔结构的支架。构建灌注式生物反应器系统,实现氧气和营养物质的大量输送,同时产生一定流体剪应力,调节细胞功能的发挥。根据支架负型结构制造出相应的树脂原型,用磷酸钙骨水泥进行填充烧结,得到与设计相符的多孔支架。接种兔成骨细胞,分别采用静态和灌注式三维动态培养方法,观察不同培养条件下细胞在支架表面以及所构造微管道内的生长情况。试验结果表明,灌注式体外培养方法更有利于细胞在支架微管道内的存活和功能的发挥,此灌注式系统能够改善支架微管道内细胞生存的微环境,增强黏附在支架微管道内细胞的活性,促进细胞进一步的增殖和矿化基质的产生。     

Flow rates in perfusion bioreactors to maximise mineralisation in bone tissue engineering in vitro

In bone tissue engineering experiments, fluid-induced shear stress is able to stimulate cells to produce mineralised extracellular matrix (ECM). The application of shear stress on seeded cells can for example be achieved through bioreactors that perfuse medium through porous scaffolds. The generated mechanical environment (i.e. wall shear stress: WSS) within the scaffolds is complex due to the complexity of scaffold geometry. This complexity has so far prevented setting an optimal loading (i.e. flow rate) of the bioreactor to achieve an optimal distribution of WSS for stimulating cells to produce mineralised ECM. In this study, we demonstrate an approach combining computational fluid dynamics (CFD) and mechano-regulation theory to optimise flow rates of a perfusion bioreactor and various scaffold geometries (i.e. pore shape, porosity and pore diameter) in order to maximise shear stress induced mineralisation. The optimal flow rates, under which the highest fraction of scaffold surface area is subjected to a wall shear stress that induces mineralisation, are mainly dependent on the scaffold geometries. Nevertheless, the variation range of such optimal flow rates are within 0.5–5 mL/min (or in terms of fluid velocity: 0.166–1.66 mm/s), among different scaffolds. This approach can facilitate the determination of scaffold-dependent flow rates for bone tissue engineering experiments in vitro, avoiding performing a series of trial and error experiments.     

Shear-stress dependence of dinoflagellate bioluminescence

Fluid flow stimulates bioluminescence in dinoflagellates. However, many aspects of the cellular mechanotransduction are incompletely known. The objective of our study was to formally test the hypothesis that flow-stimulated dinoflagellate bioluminescence is dependent on shear stress, signifying that organisms are responding to the applied fluid force. The dinoflagellate Lingulodinium polyedrum was exposed to steady shear using simple Couette flow in which fluid viscosity was manipulated to alter shear stress. At a constant shear rate, a higher shear stress due to increased viscosity increased both bioluminescence intensity and decay rate, supporting our hypothesis that bioluminescence is shear-stress dependent. Although the flow response of non-marine attached cells is known to be mediated through shear stress, our results indicate that suspended cells such as dinoflagellates also sense and respond to shear stress. Shear-stress dependence of flow-stimulated bioluminescence in dinoflagellates is consistent with mechanical stimulation due to direct predator handling in the context of predator-prey interactions.     

Scaling-down biopharmaceutical production processes via a single multi-compartment bioreactor (SMCB)

Biopharmaceutical production processes often use mammalian cells in bioreactors larger than 10,000 L, where gradients of shear stress, substrate, dissolved oxygen and carbon dioxide, and pH are likely to occur. As former tissue cells, producer cell lines such as Chinese hamster ovary (CHO) cells sensitively respond to these mixing heterogeneities, resulting in related scenarios being mimicked in scale-down reactors. However, commonly applied multi-compartment approaches comprising multiple reactors impose a biasing shear stress caused by pumping. The latter can be prevented using the single multi-compartment bioreactor (SMCB) presented here. The exchange area provided by a disc mounted between the upper and lower compartments in a stirred bioreactor was found to be an essential design parameter. Mimicking the mixing power input at a large scale on a small scale allowed the installation of similar mixing times in the SMCB. The particularities of the disc geometry may also be considered, finally leading to a converged decision tree. The work flow identifies a sharply contoured operational field comprising disc designs and power input to install the same mixing times on a large scale in the SMCB without the additional shear stress caused by pumping. The design principle holds true for both nongassed and gassed systems.     

Oscillating Couette flow for in vitro cell loading

Synovial joints are loaded by weight bearing, stretching, and fluid-driven shear. To simulate in vitro fluid-driven shear, we developed an "oscillating Couette flow mechanical shear loader". Oscillating Couette flow mimics relative motion of articular surfaces; hence, characterizing flow-induced shear by the loader enhances understanding of mechanotransduction in the joint tissue. Here, the analytical and computational models for an oscillating Couette flow were used to predict time-varying shear distribution on a plate surface, applying numerical simulation to evaluate the effects of finite plate dimension in a 2D flow. Shear stress on the plate was significantly different from that in simpler models (unbounded plates and viscous low-frequency flow). High-stress spots appeared near the leading and trailing edges of a moving plate, and a relatively uniform shear region was restricted to the interior area. Stress prediction in an example experimental geometry is presented, where the frequency and finite width effects are feasibly accounted.     

Vortex-mediated mechanical stress induces integrin-dependent cell adhesion mediated by inositol 1,4,5-trisphosphate-sensitive Ca2+ release in THP-1 cells

In the downstream regions of stenotic vessels, cells are subjected to a vortex motion under low shear forces, and atherosclerotic plaques tend to be localized. It has been reported that such a change of shear force on endothelial cells has an atherogenic effect by inducing the expression of adhesion molecules. However, the effect of vortex-induced mechanical stress on leukocytes has not been investigated. In this study, to elucidate whether vortex flow can affect the cell adhesive property, we have examined the effect of vortex-mediated mechanical stress on integrin activation in THP-1 cells, a monocytic cell line, and its signaling mechanisms. When cells are subjected to vortex flow at 400-2,000 rpm, integrin-dependent cell adhesion to vascular cell adhesion molecule-1 or fibronectin increased in a speed- and time-dependent manner. Next, to examine the role of Ca(2+) in this integrin activation, various pharmacological inhibitors involved in Ca(2+) signaling were tested to inhibit the cell adhesion. Pretreatment of cells with BAPTA-AM, thapsigargin +NiCl(2), or U-73122 (a phospholipase C inhibitor) inhibited cell adhesion induced by vortex-mediated mechanical stress. We also found that W7 (a calmodulin inhibitor) blocked the cell adhesion. However, pretreatment of cells with GdCl(3), NiCl(2), or ryanodine did not affect the cell adhesion. These data indicate that vortex-mediated mechanical stress induces integrin activation through calmodulin and inositol 1,4,5-trisphosphate-mediated Ca(2+) releases from intracellular Ca(2+) stores in THP-1 cells.     

Homogeneous batch cultures of<Emphasis Type="Italic"> Aspergillus oryzae</Emphasis> by elimination of wall growth in the Variomixing bioreactor

A novel principle for mixing and aeration in stirred bioreactors, named Variomixing, was developed. Four baffles are rotated intermittently at a rotational speed slower or similar to the speed of a centrally placed axial flow impeller. Rotational speeds of the baffles and impeller of 5–10 and 500–600 rpm, respectively, results in the highly turbulent flow regime characteristic of conventional bioreactors with high mixing and mass transfer capacities. Stagnant zones around crevices and crannies in which wall growth may commence are avoided since the baffles are never completely at rest. Increasing the rotational speed of the baffles (5 s every 5 min), so that it follows the speed of the impeller (500–600 rpm), cancels the effect of the baffles and a deep vortex and high peripheral liquid flow rates at the reactor wall develop. The vortex ensures that also the head-space of the reactor wall is flushed and any deposits removed. The filamentous fungus Aspergillus oryzae has been grown in batch cultures in the Variomixing bioreactor. Compared to conventional laboratory-scale bioreactors, in which more than 30% of all biomass was found attached to walls, less than 2% of the total A. oryzae biomass was found on the walls in the Variomixing bioreactor.     

Shear stress magnitude and duration modulates matrix composition and tensile mechanical properties in engineered cartilaginous tissue

Cartilage tissue‐engineering strategies aim to produce a functional extracellular matrix similar to that of the native tissue. However, none of the myriad approaches taken have successfully generated a construct possessing the structure, composition, and mechanical properties of healthy articular cartilage. One possible approach to modulating the matrix composition and mechanical properties of engineered tissues is through the use of bioreactor‐driven mechanical stimulation. In this study, we hypothesized that exposing scaffold‐free cartilaginous tissue constructs to 7 days of continuous shear stress at 0.001 or 0.1 Pa would increase collagen deposition and tensile mechanical properties compared to that of static controls. Histologically, type II collagen staining was evident in all construct groups, while a surface layer of type I collagen increased in thickness with increasing shear stress magnitude. The areal fraction of type I collagen was higher in the 0.1‐Pa group (25.2 ± 2.2%) than either the 0.001‐Pa (13.6 ± 3.8%) or the static (7.9 ± 1.5%) group. Type II collagen content, as assessed by ELISA, was also higher in the 0.1‐Pa group (7.5 ± 2.1%) compared to the 0.001‐Pa (3.0 ± 2.25%) or static groups (3.7 ± 3.2%). Temporal gene expression analysis showed a flow‐induced increase in type I and type II collagen expression within 24 h of exposure. Interestingly, while the 0.1‐Pa group showed higher collagen content, this group retained less sulfated glycosaminoglycans in the matrix over time in bioreactor culture. Increases in both tensile Young's modulus and ultimate strength were observed with increasing shear stress, yielding constructs possessing a modulus of nearly 5 MPa and strength of 1.3 MPa. This study demonstrates that shear stress is a potent modulator of both the amount and type of synthesized extracellular matrix constituents in engineered cartilaginous tissue with corresponding effects on mechanical function. Biotechnol. Bioeng. 2009; 104: 809–820 © 2009 Wiley Periodicals, Inc.     

Blood's critical Taylor number and its flow behavior at supercritical Taylor numbers

When the inner cylinder of a fluid-filled Couette viscometer is rotated rapidly, a vortical flow pattern develops when a dimensionless value referred to as the critical Taylor number (Tc) is reached. We have determined its magnitude in our viscometer for three Newtonian fluids and for blood at 37 degrees C, using the inflection point of torque/RPM vs. RPM (sudden rise in apparent viscosity). Its position was identified by least squares line fitting. Because blood was studied, the viscosity used in Tc calculation was the apparent bob shear stress/shear rate ratio at the inflection marking vortical flow onset. For glycerol-water mixtures Tc was 41.8 +/- 0.3 (N = 11), for propylene glycol 42.0 +/- 0.2 (N = 14), for silicone oil 41.8 +/- 0.2 (N = 11). For healthy blood Tc was 40.7 +/- 0.9 (N = 140). This evidence against blood's increased resistance to flow instability was accompanied by a slower rate of rise in torque both above and below Tc compared to the three Newtonian fluids. Newtonian fluids and blood both developed wavy vortical flow at a rotation rate moderately higher than Tc. Blood resisted this unstable flow behavior more than the Newtonian fluids but it also experienced a slower rate of rise in torque with increasing rotation rate above the critical Taylor number. Shear-thinning is the simplest explanation for blood's mildly altered Taylor vortex behavior; blood's resistance to flow instability is otherwise not found to be sufficient to affect its flow stability in man.     

Microfabricated grooved substrates as platforms for bioartificial liver reactors

An extracorporeal bioartificial liver device has the potential to provide temporary hepatic support for patients with liver failure. Our goal was to optimize the flow environment for the cultured hepatocytes in a flat-plate bioreactor, specifically focusing on oxygen delivery using high medium flow rates while reducing the detrimental effects of the resulting shear stresses. We used photolithographic techniques to fabricate microgrooves onto the underlying glass substrate. The microgrooves, perpendicular to the axial flow direction, protected the hepatocytes from the shear stress induced by the flowing medium. Using finite element analysis, we found that the velocity gradient change near the cell surface (i.e., bottom of the grooves) was smaller than that near the top surface of the flow channel, indicating that the grooves would provide protection to the attached cells from the mechanical effects of the flowing medium. We also determined that the shear stress at the cell surface could be reduced by as much as 30 times (channel height of 100 microm) in the grooved-substrate (0.5 dyn/cm(2)) bioreactor compared to the flat-substrate (15 dyn/cm(2)) bioreactor for a medium flow rate of 4.0 mL/min. Albumin and urea synthesis rates of hepatocytes cocultured with 3T3-J2 fibroblasts remained stable over 5 days of perfusion in the grooved-substrate bioreactor, whereas in the flat-substrate bioreactor they decreased over the same time period. These studies indicate that under "high" flow conditions the microgrooved-substrate in the bioreactor can decrease the detrimental effects of shear stress on the hepatocytes while providing adequate oxygenation, thereby resulting in stable liver-specific function.     

Design of a novel rotating wall bioreactor for the in vitro simulation of the mechanical environment of the endothelial function

Endothelial cells (ECs), besides being a permeability barrier between the blood and vessel wall, perform many important functions, e.g., cell migration, remodeling, proliferation, and the production, secretion and metabolism of biochemical substances, as well as the regulation of contractility of vascular smooth muscle cells (SMCs). Their function is modulated by chemical ligands as well as mechanical factors. The mechanical stresses acting on the vessel wall include the normal and circumferential stresses that result from the action of blood pressure, the shear stress that acts parallel to the luminal surface of the vessel due to blood flow and the magnitude and orientation of the gravitation field. The aim of this work was to design and construct a novel bioreactor for the stimulation of endothelial cells in vitro with a combination of mechanical factors that simulates their in vivo environment.     

Mammalian cell damage in a novel membrane bioreactor

The experimental study has assessed a novel membrane bioreactor for mammalian cell culture. In the absence of a gas phase, the key features of cell damage associated with laminar and turbulent flow have been identified. The bioreactor employs a dimpled membrane in order to enhance transverse mixing in a narrow channel, but a fall in viable cell density has been observed at Reynolds numbers above Re = 83. In the laminar flow regime wall shear is the critical mechanism and an accurate calculation of shear rate in a complex channel has been achieved using the Reynolds analogy. Flow generating a wall shear rate in excess of 3000 s(-1) has been shown to cause damage. Power dissipation measurements have been used to distinguish between laminar and turbulent flow and also to predict Kolmogorov eddy lengths. An additional turbulent bulk stress damage mechanism at higher Reynolds numbers (Re > 250) results in a very rapid fall in viable cell density.     

Insights into interstitial flow,shear stress,and mass transport effects on ECM heterogeneity in bioreactor-cultivated engineered cartilage hydrogels

Interstitial flow in articular cartilage is secondary to compressive and shear deformations during joint motion and has been linked with the well-characterized heterogeneity in structure and composition of its extracellular matrix. In this study, we investigated the effects of introducing gradients of interstitial flow on the evolution of compositional heterogeneity in engineered cartilage. Using a parallel-plate bioreactor, we observed that Poiseuille flow stimulation of chondrocyte-seeded agarose hydrogels led to an increase in glycosaminoglycan and type II collagen deposition in the surface region of the hydrogel exposed to flow. Experimental measurements of the interstitial flow fields based on the fluorescence recovery after photobleaching technique suggested that the observed heterogeneity in composition is associated with gradients in interstitial flow in a boundary layer at the hydrogel surface. Interestingly, the interstitial flow velocity profiles were nonlinearly influenced by flow rate, which upon closer examination led us to the original observation that the apparent hydrogel permeability decreased exponentially with increased interfacial shear stress. We also observed that interstitial flow enhances convective mass transport irrespective of molecular size within the boundary layer near the hydrogel surface and that the convective contribution to transport diminishes with depth in association with interstitial flow gradients. The implications of the nonlinearly inverse relationship between the interfacial shear stress and the interstitial flux and permeability and its consequences for convective transport are important for tissue engineering, since porous scaffolds comprise networks of Poiseuille channels (pores) through which interstitial flow must navigate under mechanical stimulation or direct perfusion.     

Control of the shape of a thrombus-neointima-like structure by blood shear stress

Fluid mechanical factors are thought to influence vascular morphogenesis. Here we show how blood shear stress regulates the shape of a thrombus-neointima-like tissue on a polymer micro-cylinder implanted in the center of the rat vena cava with the micro-cylinder perpendicular to blood flow. In this model, the micro-cylinder is exposed to a laminarflow with a known shear stress field in the leading region and a vortexflow in the trailing region. At 1, 5, 10, 20, and 30 days after implantation, it was found that the micro-cylinder was encapsulated by a thrombus-neointima-like tissue with a streamlined body profile. The highest growth rate of the thrombus-neointima-like tissue was found along the trailing and leading stagnation edges of the micro-cylinder. Blood shear stress in the laminar flow region was inversely correlated with the rate of thrombus formation and cell proliferation, and the percentage of smooth muscle a actin-positive cells. These biological changes were also found in the trailing vortex flow region, which was associated with lowered shear stress. These results suggest that blood shear stress regulates the rate of thrombus and neointimal formation and, thus, influences the shape of the thrombus-neointima-like structure in the present model.     

Small-scale liquid mixing in a bioreactor column with xanthan-gum simulated filamentous media

Using the heat pulse technique, the local mean flow liquid velocity and the mixing conditions for twophase flow in the riser of an airlift bioreactor have been measured and analysed. Xanthan-gum solutions were used as the physical model to some filamentous broths reported in the literature. A two-fold decrease of liquid velocity and diffusional mixing regime are predicted for the course of a fermentation process proceeding in a non-Newtonian biomass growth circulation system.