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Advanced Therapy Medicinal Products (ATMP) provide promising treatment options particularly for unmet clinical needs, such as progressive and chronic diseases where currently no satisfying treatment exists. Especially from the ATMP subclass of Tissue Engineered Products (TEPs), only a few have yet been translated from an academic setting to clinic and beyond. A reason for low numbers of TEPs in current clinical trials and one main key hurdle for TEPs is the cost and labor-intensive manufacturing process. Manual production steps require experienced personnel, are challenging to standardize and to scale up. Automated manufacturing has the potential to overcome these challenges, toward an increasing cost-effectiveness. One major obstacle for automation is the control and risk prevention of cross contaminations, especially when handling parallel production lines of different patient material. These critical steps necessitate validated effective and efficient cleaning procedures in an automated system. In this perspective, possible technologies, concepts and solutions to existing ATMP manufacturing hurdles are discussed on the example of a late clinical phase II trial TEP. In compliance to Good Manufacturing Practice (GMP) guidelines, we propose a dual arm robot based isolator approach. Our novel concept enables complete process automation for adherent cell culture, and the translation of all manual process steps with standard laboratory equipment. Moreover, we discuss novel solutions for automated cleaning, without the need for human intervention. Consequently, our automation concept offers the unique chance to scale up production while becoming more cost-effective, which will ultimately increase TEP availability to a broader number of patients.
The limited intrinsic self-healing capability of articular cartilage requires treatment of
cartilage defects. Material assisted and cell based therapies are in clinical practice but
tend to result in formation of mechanical inferior fibro-cartilage in long term follow up. If
a lesion has not been properly restored degenerative diseases are diagnosed as late sequela
causing pain and loss in morbidity. Complex three dimensional tissue models mimicking
physiological situation allow investigation of cartilage metabolism and mechanisms involved
in repair. A standardized and reproducible model cultured under controllable conditions
ex vivo to maintain tissue properties is of relevance for comparable studies.
Topic of this thesis was the establishment of an cartilage defect model that allows for
testing novel biomaterials and investigate the effect of defined defect depths on formation
of repair tissue.
In part I an ex vivo osteochondral defect model was established based on isolation of
porcine osteochondral explants (OCE) from medial condyles, 8 mm in diameter and 5 mm
in height. Full thickness cartilage defects with 1 mm to 4 mm in diameter were created
to define ex vivo cartilage critical size after 28 days culture with custom developed static
culture device. In part II of this thesis hydrogel materials, namely collagen I isolated from
rat tail, commercially available fibrin glue, matrix-metalloproteinase clevable poly(ethylene
glycol) polymerized with heparin (starPEGh), methacrylated poly(N-(2-hydroxypropyl)
methacrylamide mono-dilactate-poly(ethylene glycol) triblock copolymer/methacrylated
hyaluronic acid (MP/HA), thiol functionalized HA/allyl functionalized poly(glycidol)
(P(AGE/G)-HA-SH), were tested cell free and chondrocyte loaded (20 mio/ml) as implant
in 4 mm cartilage defects to investigate cartilage regeneration. Reproducible chondral
defects, 8 mm in diameter and 1 mm in height, were generated with an artificial tissue
cutter (ARTcut®) to investigate effect of defect depth on defect regeneration in part III.
In all approaches OCE were analyzed by Safranin-O staining to visualize proteoglycans
in cartilage and/or hydrogels. Immuno-histological and -fluorescent stainings (aggrecan,
collagen II, VI and X, proCollagen I, SOX9, RUNX2), gene expression analysis (aggrecan,
collagen II and X, SOX9, RUNX2) of chondrocyte loaded hydrogels (part II) and proteoglycan
and DNA content (Part I & II) were performed for detailed analysis of cartilage
regeneration.
Part I: The development of custom made static culture device, consisting of inserts in which OCE is fixed and deep well plate, allowed tissue specific media supply without
supplementation of TGF . Critical size diameter was defined to be 4 mm.
Part II: Biomaterials revealed differences in cartilage regeneration. Collagen I and fibrin
glue showed presence of cells migrated from OCE into cell free hydrogels with indication
of fibrous tissue formation by presence of proCollagen I. In chondrocyte loaded study
cartilage matrix proteins aggrecan, collagen II and VI and transcription factor SOX9 were
detected after ex vivo culture throughout the two natural hydrogels collagen I and fibrin
glue whereas markers were localized in pericellular matrix in starPEGh. Weak stainings resulted
for MP/HA and P(AGE/G)-HA-SH in some cell clusters. Gene expression data and
proteoglycan quantification supported histological findings with tendency of hypertrophy
indicated by upregulation of collagen X and RunX2 in MP/HA and P(AGE/G)-HA-SH.
Part III: In life-dead stainings recruitment of cells from OCE into empty or cell free
collagen I treated chondral defects was seen.
Separated and tissue specific media supply is critical to maintain ECM composition in
cartilage. Presence of OCE stimulates cartilage matrix synthesis in chondrocyte loaded
collagen I hydrogel and reduces hypertrophy compared to free swelling conditions and
pellet cultures. Differences in cartilage repair tissue formation resulted in preference of
natural derived polymers compared to synthetic based materials. The ex vivo cartilage
defect model represents a platform for testing novel hydrogels as cartilage materials, but
also to investigate the effect of cell seeding densities, cell gradients, cell co-cultures on
defect regeneration dependent on defect depth. The separated media compartments allow
for systematic analysis of pharmaceutics, media components or inflammatory cytokines on
bone and cartilage metabolism and matrix stability.