Tis work was supported by the National Key Research and Development Program of China (2022YFA1104600), and the Zhejiang Provincial Natural Science Foundation of China (LQ23H160011).

1. Fabrication of the 3D acoustic assembly device
<ol>
	<li>Begin by preparing four 1 mm thick PMMA sheets through laser cutting30, and then proceed to glue them together to form a square chamber with an inner width of 21 mm and a height of 10 mm.</li>
	<li>Next, attach another 1 mm thick PMMA sheet to the bottom of the chamber to serve as a holder for the bioink.</li>
	<li>Carefully affix three lead zirconate titanate (PZT) transducers (each measuring 20 mm in length, 10 mm in width, 0.7 mm in thickness, and with a primary resonant frequency of 3 MHz, see Table of Materials) to the exterior of the three orthogonal walls of the chamber, respectively. Ensure that the bottom PZT transducer is centered beneath the chamber.</li>
	<li>Solder wires to the two conductive areas of each PZT transducer.</li>
	<li>Finally, secure the device onto a hollow base to prevent the bottom PZT from coming into contact with other countertops.</li>
</ol>
2. Setting up the acoustic assembly system
<ol>
	<li>Begin by mounting the acoustic device onto a microscope stage, allowing for top-view observation of the chamber&#39;s interior.</li>
	<li>Position a digital microscope on the side of the device that is free from PZT transducers, enabling side-view observation of the chamber&#39;s interior.</li>
	<li>Independently connect the wires from the three PZT transducers in series to three power amplifiers and three output channels of function generators (see Table of Materials).</li>
	<li>Program the settings on the function generators for each PZT transducer, specifying parameters such as sinusoidal waveform, frequency, and amplitude.</li>
	<li>To ensure sterilization, fill the chamber of the acoustic device with 75% alcohol for 5 min, followed by a thorough cleaning with sterile PBS solution. Subsequently, irradiate the chamber with UV light in a clean bench for a minimum of 1 h.</li>
</ol>
3. Cell culture and harvest procedure
<ol>
	<li>Begin by culturing C3A cells, a human hepatocellular carcinoma cell line, in a T25 cell culture flask using Dulbecco&#39;s modified Eagle medium (DMEM) supplemented with 10% fetal bovine serum and 1% penicillin-streptomycin (see Table of Materials).</li>
	<li>When the C3A cells reach approximately 80% confluence, perform cell passage as follows: firstly, wash the bottom of the culture flask twice with PBS. Then, add 2 mL of 0.05% trypsin-EDTA to the cell culture flask and incubate at 37 &#176;C to facilitate cell detachment. Stop the trypsinization process by adding 2 mL of complete culture medium.</li>
	<li>Transfer the cell solution to a 15 mL tube, and centrifuge it at 200 &#215; g for 5 min at room temperature to obtain a cell pellet.</li>
</ol>
4. Preparation of the bioink
<ol>
	<li>Prepare a 6% (w/v) GelMA solution containing 0.5% (w/v) lithium phenyl-2,4,6-trimethylbenzoylphosphinate (LAP) by dissolving 0.3 g of GelMA and 0.025 g of LAP (see Table of Materials) in 5 mL of phosphate buffer solution (PBS). Allow the mixture to sit in a 47 &#176;C water bath for 1 h.</li>
	<li>Before mixing with cells, pass the GelMA solution through a 0.22 &#181;m filter (see Table of Materials) for sterilization.</li>
	<li>Resuspend the cell pellet mentioned above (step 3.3) in cell culture medium. Stain a small volume of cells with a 0.4% trypan blue solution and then use a clean hemocytometer for cell counting.</li>
	<li>Mix an appropriate amount of C3A cells, calculated based on the cell density obtained above, with the sterilized GelMA solution to prepare the bioink with a cell density of 2 &#215; 106 cells/mL.</li>
	<li>For visualization of the assembled cell spheroids, pre-stain C3A cells by incubating them with 2 &#181;M cell tracker (DiO dye, see Table of Materials) at 37 &#176;C for 20 min. Subsequently, wash the labeled cells with fresh cell culture medium three times before use.</li>
</ol>
5. Assembling the cell spheroids using the acoustic device
<ol>
	<li>Pipette more than 1 mL of the bioink into the sterilized chamber. Ensure that the face-to-face distance between the liquid surface and the chamber bottom is an integer multiple of half the acoustic wavelength. 
	NOTE: One can control this distance by adjusting the volume of bioink added. The acoustic wavelength (&#955;) can be estimated using the formula &#955; = c/f, where c represents the speed of sound in the medium, and f is the frequency of the PZT transducer.</li>
	<li>Turn on the function generator and power amplifier to initiate the actuation of each PZT transducer. 
	NOTE: It is recommended to individually actuate each PZT transducer first to achieve the optimal parallel-line cellular pattern. This can be achieved by conducting a frequency sweep with a step size of 0.001 MHz near the primary resonant frequency for each PZT transducer. Afterward, simultaneously apply these optimal signals to all three PZT transducers to obtain the expected 3D-dot cellular pattern. Before applying each input signal, ensure that the cells are evenly dispersed in the bioink by gently agitating.</li>
	<li>Crosslink the bioink using blue light (405 nm, 60 mW/cm2, 30 s) to create a 3D hydrogel scaffold that encapsulates the cell aggregates assembled acoustically. Afterward, turn off the function generator and power amplifier.</li>
	<li>Carefully transfer the 3D hydrogel scaffold from the chamber into a Petri dish and cut it into small pieces (e.g., 2 mm &#215; 2 mm &#215; 2 mm) using a clean razor.</li>
	<li>Add cell culture medium for cultivation. 
	&#8203;NOTE: Remember to change the culture medium every day.</li>
</ol>
6. Retrieving cell spheroids
<ol>
	<li>Begin by observing spheroid formation at different layers of the scaffolds using an inverted microscope.</li>
	<li>After 3 days of culture, remove the culture medium and thoroughly wash the hydrogel scaffolds twice with PBS.</li>
	<li>Incubate the scaffolds with more than 2 mL of GelMA lysis buffer at a 1: 200 dilution with cell culture medium for 30 min in a cell incubator. This step aims to dissolve the hydrogel scaffolds.</li>
	<li>Transfer the solution from the previous step into a tube and then centrifuge it at 200 &#215; g for 5 min at room temperature to obtain the cell spheroid pellet.</li>
	<li>Discard the supernatant and resuspend the pellet in fresh culture medium for downstream applications.</li>
</ol>
7. Spheroid viability analysis
<ol>
	<li>Assess the viability of cell spheroids either within the hydrogel scaffolds or in the retrieved spheroids using a live/dead staining kit (see Table of Materials).</li>
	<li>Incubate the samples at different culture time points with 1 mL of PBS solution containing 1 &#181;L of Calcein-AM and 2 &#181;L of Propidium Iodide (PI) for 15 min at 37 &#176;C.</li>
	<li>For samples within the hydrogel scaffolds, wash them directly with PBS twice. For retrieved spheroids, centrifuge at 200 &#215; g for 5 min at roomtemperature to obtain a spheroid pellet, and wash it twice before observation.</li>
	<li>Observe the samples using a fluorescence microscope and capture the fluorescence images.</li>
	<li>Calculate the ratio of the area stained with Calcein-AM to the total area stained with both Calcein-AM and PI using ImageJ to determine spheroid viability.</li>
</ol>

Scalable Generation of Uniform Cell Spheroids Using a 3D Acoustic Assembly Device

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The authors have nothing to disclose.

Efficient and stable fabrication of cell spheroids with high throughput using technologies like the 3D acoustic assembly device holds great promise for advancing biomedical engineering and drug screening1,2,3. This approach simplifies the mass production of cell spheroids through straightforward procedures.
However, there are critical factors to consider when using this acoustic device. The creation o...

3D in vitro culture models, which provide more in vivo-like structural and morphological characteristics compared to conventional 2D culture models, have been recognized as promising systems in various biomedical applications such as tissue engineering, disease modeling, and drug screening1,2,3. As one type of 3D culture model, cell spheroids typically refer to cell aggregation, creating 3D spheroidal structures characterized by enhanced cell-cell and cell-matrix interactions4,5,6. Therefore, fabricating cell spheroids has become a powerful tool for enabling diverse biological studies.
Various techniques, including hanging drop7, non-adhesive plates8, or microwell devices9, have been developed to obtain spheroids. In principle, these methods commonly facilitate cell assembly by utilizing physical forces such as gravitational force while minimizing interactions between cells and the substrate. However, they often involve labor-intensive processes, have low productivity, and pose challenges for controlling spheroid size10,11. Importantly, the production of spheroids with the desired size and uniformity in sufficient quantity is of utmost importance to satisfy specific biological applications. In contrast to the above-mentioned methods, acoustic waves, as one type of external-force-driven technique12,13,14, have shown potential for mass manufacturing of cell spheroids with high quality and throughput, based on the principle of enhancing cell aggregation through external forces15,16,17,18. Unlike electromagnetic or magnetic forces, acoustic-based cell manipulation techniques are non-invasive and label-free, enabling spheroid formation with excellent biocompatibility19,20.
Commonly, standing surface acoustic waves (SAWs) and bulk acoustic waves (BAWs)-based devices have been developed to generate spheroids, utilizing the acoustic nodes (ANs) produced by corresponding standing acoustic fields21,22,23. Particularly, acoustic assembly devices based on BAWs, with the merits of convenient manufacture, easy operation, and excellent scalability, have gained attention for fabricating cell spheroids24,25. We have recently developed a facile BAWs-based acoustic assembly device with the ability to generate spheroids with high throughput26. The proposed device consists of a square polymethyl methacrylate (PMMA) chamber with three lead zirconate titanate (PZT) transducers arranged respectively in the X/Y/Z plane. This arrangement enables the creation of a 3D dot-array pattern of levitated acoustic nodes (LANs) for driving cell assembly. Compared to previously reported BAWs- or SAWs-based devices, which can only create a 1D or 2D array of ANs27,28,29, the present device enables a 3D dot-array of LANs for rapid cell aggregate formation within the gelatin methacryloyl (GelMA) solution. Subsequently, cell aggregates matured into spheroids with high viability within the photocured GelMA scaffolds after three days of cultivation. Finally, a large number of spheroids with uniform size were easily obtained from the GelMA scaffolds for downstream applications.

<table border="1" fo:keep-together.within-page="1" fo:keep-with-next.within-page="always">
	<tbody>
		<tr>
			<td>0.22-&#956;m filter</td>
			<td>Merck</td>
			<td>SLGSM33SS</td>
			<td>Used for GelMA solution sterilization</td>
		</tr>
		<tr>
			<td>35 mm-cell culture dish</td>
			<td>Corning</td>
			<td>430165</td>
			<td>Used for culturing cells</td>
		</tr>
		<tr>
			<td>Confocal microscope</td>
			<td>Nikon</td>
			<td>A1RHD25</td>
			<td>Fluorescent cell observation</td>
		</tr>
		<tr>
			<td>DiO dye</td>
			<td>Beyotime</td>
			<td>C1038</td>
			<td>Dye used to stain cells</td>
		</tr>
		<tr>
			<td>DMEM</td>
			<td>Gibco</td>
			<td>12430054</td>
			<td>Cell culture media</td>
		</tr>
		<tr>
			<td>FBS</td>
			<td>Gibco</td>
			<td>10099141C</td>
			<td>Cell culture media supplement</td>
		</tr>
		<tr>
			<td>Function generator</td>
			<td>Rigol</td>
			<td>DG5352</td>
			<td>For RF signal generation</td>
		</tr>
		<tr>
			<td>GelMA</td>
			<td>Regenovo</td>
			<td>none</td>
			<td>Used to prepare bioink</td>
		</tr>
		<tr>
			<td>GelMA lysis buffer</td>
			<td>EFL</td>
			<td>EFL-GM-LS-001</td>
			<td>Used to dissolve GelMA scaffolds</td>
		</tr>
		<tr>
			<td>Inverted microscope</td>
			<td>Nikon</td>
			<td>Ti-U</td>
			<td>Cell observation</td>
		</tr>
		<tr>
			<td>LAP</td>
			<td>Sigma-Aldrich</td>
			<td>900889</td>
			<td>Used as photoinitiator</td>
		</tr>
		<tr>
			<td>Live-Dead kit</td>
			<td>Beyotime</td>
			<td>C2015M</td>
			<td>Cell vability analysis</td>
		</tr>
		<tr>
			<td>PBS</td>
			<td>Gibco</td>
			<td>10010002</td>
			<td>Used as buffer</td>
		</tr>
		<tr>
			<td>Penicillin-streptomycin</td>
			<td>Gibco</td>
			<td>15070063</td>
			<td>Prevent cell culture contamination</td>
		</tr>
		<tr>
			<td>Power amplifer</td>
			<td>Minicircuit</td>
			<td>LCY-22+</td>
			<td>Increase the voltage amplitude of the RF signal</td>
		</tr>
		<tr>
			<td>PZT transducers</td>
			<td>Yantai Xingzhiwen Trading Co.,Ltd.</td>
			<td>PZT-41</td>
			<td>Functional units for acoustic assembly device</td>
		</tr>
		<tr>
			<td>T25 cell culture flask</td>
			<td>Corning</td>
			<td>430639</td>
			<td>Used for culturing cells</td>
		</tr>
		<tr>
			<td>Trypan blue&#160;</td>
			<td>Gibco</td>
			<td>15250061</td>
			<td>Cell counting</td>
		</tr>
		<tr>
			<td>Trypsin-EDTA&#160;</td>
			<td>Gibco</td>
			<td>25200056</td>
			<td>Cell dissociation enzyme</td>
		</tr>
	</tbody>
</table>

three-dimensional acoustic assembly device for mass manufacturing of cell spheroids

Cell spheroids are promising three-dimensional (3D) models that have gained wide applications in many biological fields. This protocol presents a method for manufacturing high-quality and high-throughput cell spheroids using a 3D acoustic assembly device through maneuverable procedures. The acoustic assembly device consists of three lead zirconate titanate (PZT) transducers, each arranged in the X/Y/Z plane of a square polymethyl methacrylate (PMMA) chamber. This configuration enables the generation of a 3D dot-array pattern of levitated acoustic nodes (LANs) when three signals are applied. As a result, cells in the gelatin methacryloyl (GelMA) solution can be driven to the LANs, forming uniform cell aggregates in three dimensions. The GelMA solution is then UV-photocured and crosslinked to serve as a scaffold that supports the growth of cell aggregates. Finally, masses of matured spheroids are obtained and retrieved by subsequently dissolving the GelMA scaffolds under mild conditions. The proposed new 3D acoustic cell assembly device will enable the scale-up fabrication of cell spheroids, and even organoids, offering great potential technology in the biological field.

Author Spotlight: Development of a Scaffold-Free Acoustic Assembly Method for High-Quality 3D Cell Spheroid Culture 

Three-Dimensional Acoustic Assembly Device for Mass Manufacturing of Cell Spheroids

3D in vitro culture models, like cell spheroids, have been widely used in the fields of tissue engineering, disease modeling, and drug screening. Our research focuses on developing and invest per engineering method to fabricate spheroids or other 3D in vitro culture models with high quality for diverse biological studies. In the current protocol, the spheroids grew within the GelMA scaffold and are retrieved at the final layback, dissolving the scaffold, causing additional procedures.We will try to acoustically assemble cell aggregates in a cultural medium to enable them to grow within spheroids without scaffold. Compared to magnetic assembly techniques, acoustic waves can directly assemble cells in a label-free manner without potential toxic effects on cells. Besides, our protocol enables cell spheroids to be assembled in a three-dimensional array, substantially increasing throughput.

This study designed a 3D acoustic assembly device for mass manufacturing of cell spheroids. The acoustic device comprised a square chamber with two PZT transducers attached to the X-plane and Y-plane on the outer surface of the chamber and one PZT transducer on the chamber&#39;s bottom (Figure 1A,B). Three output channels from two function generators were connected to three power amplifiers to generate three independently sinusoidal signals to actuate the PZT transducers (<s...

Watch this Scientific Journal Video about Development of a Scaffold-Free Acoustic Assembly Method for High-Quality 3D Cell Spheroid Culture at JoVE.com

Cell spheroids have been considered one potential model in the field of biological applications. This article describes protocols for scalably generating cell spheroids using a 3D acoustic assembly device, which provides an efficient method for the robust and rapid fabrication of uniform cell spheroids.

Cell spheroids are promising three-dimensional (3D) models that have gained wide applications in many biological fields. This protocol presents a method ...

three-dimensional-acoustic-assembly-device-for-mass-manufacturing

Research

JoVE Journal

Bioengineering

Setting Up an Acoustic Assembly System and Cell Culture Harvesting for Generating Uniform Cell Spheroids

To begin, sterilize the chamber of the acoustic device with 75%alcohol for five minutes. Then, clean the device with sterile PBS and irradiate it with UV light for one hour. Mount the sterile acoustic device onto a microscope stage for top-view observation of the chamber's interior.Position a digital microscope on the side of the device that is free from PZT transducers, enabling side-view observation of the chamber's interior. Independently connect the wires from the three PZT transducers in series to three power amplifiers and three output channels of function generators. Program the settings on the function generators for each PCT transducer, specifying parameters such as sinusoidal waveforms, frequency, and amplitude.Culture 3CA cells in DMEM supplemented with 10%FBS and 1%penicillin streptomycin in a T25 cell culture flask. When the cells become 80%confluent, wash the culture twice with PBS. After removing the PBS, add two milliliters of 0.05%trypsin-EDTA to the flask and incubate at 37 degrees Celsius for cell detachment.Add two milliliters of complete cell culture medium into the flask to stop the trypsinization. Transfer the cell suspension to a 15-milliliter tube and centrifuge at 200 G for five minutes.

Bioink Preparation, Acoustic Device Assembly, and Viability Analysis of Cell Spheroids

To prepare the bio ink solution mix an appropriate amount of C3A cell suspension with the sterilized gelMA solution. Prestain the C3A cell spheroids with two micromolar cell tracker solution at 37 degrees for 20 minutes. To wash the cells, first, remove the supernatin by centrifuging and then add fresh cell culture medium.Add at least two milliliters of bio ink into the sterilized acoustic device chamber. Turn on the function generator and power amplifier to initiate the actuation of each PZT transducer to generate a 3D array of cell aggregates. Crosslink the bio ink using blue light for 30 seconds to create 3D hydrogel scaffolds, encapsulating the assembled cell aggregates acoustically.Next, carefully transfer the 3D hydrogel scaffold from the chamber into a Petri dish. Cut it into small pieces using a clean razor, and then add cell culture medium into the Petri dish. Incubate the C3A cell spheroids at different culture time points in one milliliter of PBS containing one microliter of calcium am and two microliters of propidium iodide for 15 minutes at 37 degrees Celsius.Rinse the sample embedded in hydrogel scaffolds twice with PBS. For retrieved spheroids, perform centrifugation at 200 G for five minutes and wash twice with PBS. Using a fluorescence microscope, observe the spheroids and capture the images.The cell aggregates were arranged in the regular 3D dot array pattern with a green fluorescent signal. The assembled C3A gelMA aggregates gradually integrated and formed tight spheroids by day three, accompanied by an increase in spheroid diameter. The viability of the cell spheroids remained good before day three, but slightly decreased after a week of culture.The released spheroids maintained a good spherical morphology with a narrow size distribution along with desirable viability and expression of albumin.

772 Views.  Hangzhou Dianzi University.  Cell spheroids have been considered one potential model in the field of biological applications. This article describes protocols for scalably generating cell spheroids using a 3D acoustic assembly device, which provides an efficient method for the robust and rapid fabrication of uniform cell spheroids.

Scalable Generation of Uniform Cell Spheroids Using a 3D Acoustic Assembly Device

Summary