2.1. Production and Structural Characterization of 3D Porous PEGDA Hydrogels
3D porous PEGDA hydrogels were fabricated by combining gas foaming and UV-induced crosslinking. Gas foaming commonly requires mixing foaming agents with a prepolymer solution, leading to the release of gas bubbles that become trapped within the hydrogel matrix during polymerization, resulting in porous structures. While polymerization is often induced by non-photocurable initiators or temperature changes [
28,
29,
30], in this study, UV-induced crosslinking was the chosen method, with sodium bicarbonate and acetic acid serving as the foaming agents. This approach, previously used to produce porous PEG-based hydrogels [
31,
32,
33], offered a superior control over hydrogel crosslinking and allowed a notable reduction in polymerization from 30 minutes [
29] to 45 seconds.
Different formulations of 20% PEGDA hydrogels were prepared by adjusting the gas foaming and crosslinking parameters to optimize scaffold porosity and pore size. The resulting scaffolds displayed a porous foam structure with a thickness of approximately 6-8 mm, notably higher than the non-porous PEGDA hydrogels produced solely via UV crosslinking, as illustrated in
Figure 1.
Initially, we evaluated the effect of the foaming agents’ concentration on scaffold morphology using two formulations based on a prior study by Poursamar et al. [
34]: 6% sodium bicarbonate with 6.75% acetic acid and 10% sodium bicarbonate with 11.25% acetic acid. SEM analysis revealed that increasing the concentration of the foaming agents resulted in thicker and more heterogeneous scaffolds, exhibiting regions lacking pores alongside areas with larger pores, as depicted in
Figure 2A. Conversely, the lowest concentrations of sodium bicarbonate and acetic acid yielded scaffolds with smaller and more evenly distributed pores. Hence, the amount of porogen particles and the degree of gas foaming influenced scaffold porosity, as previously evidenced by Lim et al. [
35]. Similar outcomes were reported by Nam et al. [
36] in PLLA scaffolds fabricated using the gas foaming technique with ammonium bicarbonate. Given the higher homogeneity in pore size, the lowest porogen concentration was selected for further tests.
Next, we examined how the photoinitiator concentration affected the scaffold pore characteristics, using concentrations of 0.1%, 0.45% and 0.95% (v/v) respectively. As observed in
Figure 2B, all scaffold formulations exhibited spherical-shaped pores evenly dispersed throughout the scaffold thickness. Typically, foam stabilizers such as surfactants are used in gas foaming to prevent liquid drainage and bubble coalescence, promoting the formation of more homogenous foams [
37]. However, since foam stabilizers were not used in this study, the observed homogeneity was likely achieved through the strategic placement of sodium bicarbonate at the bottom of the well, rather than its dispersion within the prepolymer solution. Additionally, higher photoinitiator concentrations resulted in a reduction in the average pore size and pore size distribution, as illustrated in
Figure 2C: pore sizes of 800 ± 260 µm, 319 ± 121 µm, and 233 ± 60 µm were observed for photoinitiator concentrations of 0.1%, 0.45% and 0.95%, respectively. These results were expected, as increased photoinitiator concentration implies a faster crosslinking, resulting in more stable foams that limit bubble coalescence and the formation of larger pores [
27].
Micro-computed tomography (Micro-CT) analysis corroborated these findings (
Figure 3), demonstrating increased scaffold porosity and interconnectivity with higher photoinitiator concentrations. The porosity ranged from 41.5% to 64.5%, consistent with the porosity of porous 20% PEGDA hydrogels reported by Sannino et al. [
31] (64.29-68.43%). However, the authors reported smaller pore sizes of 55.6-92.1 µm, likely due to the lower concentration of sodium bicarbonate used (40 mg/ml). For the 0.95% photoinitiator formulation, interconnectivity reached 100%, implying that all pores were accessible for cell seeding, migration and nutrient/oxygen flow [
38].
The water content and swelling degree of the three formulations of porous scaffolds were evaluated alongside non-porous scaffolds with 0.95% photoinitiator concentration. All porous scaffolds exhibited a water content exceeding 89% (
Figure 4A), whereas the non-porous scaffold displayed a water content of 81%, in line with the results of Nguyen et al. [
39] and consistent with the water content reported for cartilage tissue (approximately 80%) [
1]. Additionally, water content increased with photoinitiator concentration, albeit not significantly.
The porous hydrogels displayed similar swelling behaviors, reaching swelling degrees of 23.7 ± 3.7%, 61.4 ± 6.0% and 58.4 ± 6.3% after 24h, for photoinitiator concentrations of 0.1%, 0.45% and 0.95%, respectively (
Figure 4B). The swelling degree increased rapidly during the initial 1-3 h and stabilized thereafter, due to the established equilibrium between the ions present in the hydrogel and the surrounding medium [
40]
. Particularly, the hydrogels with 0.1% photoinitiator concentration had a lower swelling degree compared to those with higher concentrations, possibly due to their reduced thickness and consequently reduced available surface for water uptake. In contrast, the non-porous hydrogels exhibited a distinct swelling behavior, with a swelling degree of approximately -10% throughout the 24h-peroid, indicating that their polymer network was likely highly compacted and restricted water uptake.
In TE, scaffold pore size plays a pivotal role in facilitating cell penetration, migration, nutrient diffusion and removal of metabolic waste [
41]. Several studies have reported differing optimum ranges for cell penetration and chondrogenic differentiation for cartilage TE, depending on factors such as cell type, biomaterial and the chosen architecture. For chondrocytes, scaffold pore sizes of 150-300 µm have been shown to promote cell proliferation and the synthesis of cartilage ECM components, including collagen type II and GAGs [
42,
43,
44]. Conversely, Yamane et al. [
45] observed enhanced chondrocyte proliferation and ECM synthesis in scaffolds with pore size of 400 µm, possibly due to differences in scaffold hydrophilicity and biomaterials used. Regarding adipose stem/stromal cells (ASCs), various pore size ranges have been suggested for chondrogenic differentiation, including 100-150 µm [
46], 200-300 µm [
47] and 350-450 µm [
48]. Im et al. [
49] reported that scaffolds with pore size of 400 µm promoted enhanced proteoglycan production and expression of cartilage gene markers, while scaffolds with pore size of 200 µm enhanced cell proliferation. Similar findings were reported by Oh et al. [
50], who compared pore sizes of 370-400 µm to 90-105 µm. For MSCs, a pore size of 170-500 µm has been identified to support chondrogenesis [
51,
52]. Within this range, Matsiko et al. [
53] found that scaffolds with a pore size of 300 µm enhanced cell proliferation, chondrogenic gene expression and cartilage-like matrix deposition. Considering the broad range of pore sizes deemed suitable for MSC proliferation and chondrogenic differentiation, we chose to seed MSCs in the scaffold with 0.95% photoinitiator concentration. This formulation exhibited a pore size range of 170-290 µm and higher interconnectivity in comparison with the other formulations tested.
The mechanical properties, including compressive modulus, strength and elastic recovery, were assessed for both non-porous and porous hydrogels with 0.95% photoinitiator concentration. While all scaffolds exhibited elastomeric behavior (
Supplementary Figure S1), porous scaffolds did not break under the applied strain, rendering the evaluation of their compressive strength impossible. Conversely, non-porous hydrogels presented a compressive strength of 77 ± 5 kPa and a compressive modulus of 180 ± 8 kPa, as shown in Figure 5. These values align with the compressive modulus of PEGDA hydrogels reported by Xiao et al. [
54] (183 ± 14 kPa) and Moura et al. [
55] (210 ± 20 kPa). However, other studies have reported different compressive modulus for 20% PEGDA hydrogels, including 69-83 kPa [
56], 250 kPa [
39] and 424-560 kPa [
57,
58,
59], likely due to the different crosslinking mechanisms and the molecular weight of the PEGDA precursor used. The compressive modulus of the porous hydrogels was notably lower compared to their non-porous counterparts, measuring at 40 ± 10 kPa, 48 ± 1 kPa and 53 ± 9 kPa with photoinitiator concentrations of 0.1%, 0.45% and 0.95%, respectively. This was expected since porous hydrogels have a greater void volume compared with non-porous hydrogels, resulting in a reduced effective cross-sectional area, which is key for preserving the original structure under external stress [
60,
61,
62].
Additionally, the porous hydrogels exhibited high elastic recovery of 84.3-99.2%, which indicates their ability to almost readily return to their original shape, making them suitable for use under compressive loading stimuli, as constantly occurs in the articular cartilage within the knee joint. After swelling, both porous and non-porous hydrogels exhibited lower compressive moduli and compressive strength (where applicable). In porous hydrogels, this reduction is directly linked to the water uptake they experienced: as the hydrogel swells, its network density decreases, resulting in a softer material [
63]. As for the non-porous hydrogels, their decreased compressive modulus after swelling is more likely attributed to their decreased volume fraction, as evidenced by their negative swelling degree, which directly correlates with the elastic modulus [
64].
Figure 5.
(A) Compressive Modulus (kPa) and (B) compressive strength (kPa) and elastic recovery (%) of three 0.95% v/v PEGDA scaffold formulations: non-porous and porous scaffolds (after fabrication and after 1h of swelling) (n=3). #Hydrogels broke. & Hydrogels did not break. ***p<0.001; ****p<0.0001.
Figure 5.
(A) Compressive Modulus (kPa) and (B) compressive strength (kPa) and elastic recovery (%) of three 0.95% v/v PEGDA scaffold formulations: non-porous and porous scaffolds (after fabrication and after 1h of swelling) (n=3). #Hydrogels broke. & Hydrogels did not break. ***p<0.001; ****p<0.0001.
Unlike the non-porous hydrogels, the porous scaffolds exhibited a compressive modulus lower than the reported equilibrium compressive modulus for cartilage (0.08-2.1 MPa) [
65]. Yet, they may offer a more favorable environment for MSC chondrogenic differentiation compared to the non-porous scaffolds. According to Park et al. [
66], MSCs seeded on softer matrices (< 1 kPa) exhibit increased collagen type II production, in contrast to MSCs seeded on stiffer substrates. This observation has been corroborated by Steward et al. [
67] using 3D agarose scaffolds with stiffness ranging from 0.5 kPa to 25 kPa. The authors propose that, although this stiffness range does not fully replicate that of mature human cartilage, it may simulate the cartilage environment during its developmental stage, potentially aiding in MSC differentiation into a cartilage phenotype [
66].
2.3. Chondrogenic Differentiation of MSC-Spheroids on 3D Porous PEGDA Hydrogels
Spheroids of MSCs, each comprising 400 cells, were generated in Aggrewell plates. After 24 h, the spheroids were seeded onto the 3D porous PEGDA hydrogels and cultured in chondrogenic medium for 21 days (
Figure 7A). MSCs were employed for their potential to differentiate into chondrocytes and their capacity for extensive in vitro expansion, while the use of spheroids was preferred over single cells to promote cell-cell contact and mimic the cartilaginous condensations characteristic of embryonic development [
72].
Prior to seeding, the spheroids exhibited a spherical and compact morphology, with an average diameter of 157 ± 8 µm, as illustrated in
Figure 7B. Their dimensions closely matched the pore size range of the scaffold, indicating potential for effective colonization of the construct. Additionally, it has been reported that aggregates of similar size exhibit superior chondrogenic differentiation compared to 1-2 mm pellets [
73].
After 21 days of culture, Safranin-O stainings showed that the MSC-derived spheroids were localized within the pores of the scaffold (
Supplementary Figure S2). The aggregates retained their initial spherical morphology and most cells within the aggregate remained viable, as shown in
Figure 8A. Although a small number of dead cells were observed, no necrotic center was evident, largely due to the small diameter of the aggregates, which allowed sufficient oxygen distribution. Alcian Blue and Safranin-O stainings performed on the final spheroids further revealed the presence of proteoglycans and GAGs, respectively, both typical components of the articular cartilage ECM.
To assess the expression of chondrogenic markers, quantitative polymerase chain reaction (qRT-PCR) was performed on MSC aggregates at day 1 (before differentiation) and on spheroid-seeded PEGDA porous scaffolds at day 21 (after differentiation). Specifically, the expression levels of
COL1A1 (collagen type I, a marker for undifferentiated mesenchymal tissue),
COL2A1 (collagen type II, indicative of cartilaginous tissue),
SOX9 (a transcription factor for chondrogenic genes) and
ACAN (aggrecan, main cartilage proteoglycan) were evaluated and normalized to 2D MSC cultures at day 0 (before spheroid formation and scaffold seeding). As illustrated in
Figure 8B, MSC aggregates exhibited decreased expression of
COL1A1 (0.27-fold) and increased expression of
COL2A1 (7.1-fold), SOX9 (12.1-fold) and
ACAN (2.5-fold), compared to 2D MSC cultures, which is consistent with the literature [
72,
74]. This suggests that, while MSC aggregates undergo some level of pre-conditioning, their 3D configuration alone is insufficient to initiate chondrogenesis. Chondrogenic stimuli, such as medium supplemented with
TGF-βs, are still required to support proper MSC chondrogenesis [
72].
In spheroid-seeded PEGDA scaffolds, following 21 days of differentiation, a similar trend of COL1A1 downregulation and COL2A1, SOX9 and ACAN upregulation was observed, when compared to 2D culture, confirming successful chondrogenic differentiation. Notably, there was a significant increase in the expression of COL2A1 (35.9-fold) and SOX9 (41.2-fold), while ACAN levels exhibited a more moderate increase (5.7-fold). In comparison with MSC aggregates at day 1, the aggregates cultured in PEGDA porous hydrogels showed similar expression of COL1A1 but increased expression of COL2A1 (5.1-fold), SOX9 (3.4-fold) and ACAN (2.3-fold). These findings not only highlight the capacity of the 3D porous PEGDA scaffold to support chondrogenesis but also demonstrate that combining MSC aggregates with a porous PEGDA scaffold of suitable pore size might be a more effective approach for inducing chondrogenic differentiation, when compared to scaffold-free MSC aggregates and conventional 2D monolayer cultures. Hence, the spheroid-seeded 3D porous PEGDA scaffold holds significant promise for cartilage TE or in vitro OA modelling strategies.