Inspired by previously published research on surrogate head models, our preliminary experiments started by culturing neurons inside a full-size surrogate head model and then exposing them to a shock wave[35, 36]. However, a full replicate of the human head presented significant challenges and confounding experimental variables for a reduced model including a large physical size and weight, variations in neuronal sample placement, and shock wave exposure. In this study, we designed a simplified enclosure that allows a precise shockwave exposure to a primary neuronal culture. A round cylindrical enclosure symmetrically holds a sample amenable to cell culture methodology, a watertight cover that can be adjusted to varying skull material properties and thicknesses, and a surrounding media simulating cerebrospinal fluid.
In vitro Blast Injury Apparatus
One consideration with existing in vitro models is that they orient cells parallel to the shock wave propagation where cells in the front would receive a higher pressure than cell in the back[23, 30]. To guarantee that all cells receive the same blast intensity, our design ensured cells were on a plane normal the direction of blast wave motion. In addition, our initial experiments found that the use of tissue culture plastic led to 100% cell detachment after blast. We found that a compliant silicone-based cell culture substrate resolved these issues.
To develop a soft cell culture substrate for the blast apparatus, we used polydimethylsiloxane (PDMS) to create custom culture wells. This choice was guided by our previous experience in culturing neurons on PDMS in neuronal stretch injury systems[37, 38]. PDMS has many advantages that were relevant to our application. PDMS is simple to process, biocompatible and transparent for microscopy[39]. The PDMS cell culture substrate was designed with a plating area (2680 mm2) accommodating about 2 million cells per sample which is adequate for western blotting. The bottom thickness of the PDMS cell culture substrate was limited to 3mm to allow for sufficient microscopic examination. Since the design did not provide mechanical stability for handling and insertion into the blast apparatus, 10 mm thick supporting sides were formed surrounding the plating area, Fig. 1. The PDMS mold was drawn in Autodesk Fusion 360, converted into CNC machining code, and machined from a 101mm square block of aluminum on a HAAS CNC mill. The mold was polished using diamond lapping paste to achieve the best optical clarity in the PDMS. Polishing was done in 6 steps starting with 12-micron diamond paste then 8,4,2,1,0.5 micron respectively.
To cast the PDMS culture well, a PDMS kit (Sylgard 184, Dow Corning, Midland, MI, USA) was prepared by mixing base & curing agent, in a ratio of 10 parts base to 1 part curing agent by weight, agitated to remove air bubbles, poured into the mold, and cured for 45 min at 75°C. The PDMS was removed from the mold, washed with soap and water, dried, plasma cleaned for 3 minutes, and autoclaved prior to plating cells. The final product of PDMS culture wells as well as aluminum mold are shown in Figs. 1 and 2.
The blast injury apparatus consists of a custom-machined cylindrical container made from autoclavable polypropylene and a clear acrylic cover to house the neuronal culture within the shock tube, Fig. 2. The polypropylene cylinder was fabricated to fit the PDMS cell culture substrate and a rubber O-ring to liquid seal the apparatus. Two Luer lock openings on the side allow for injecting media into the sealed container and release air bubbles. We tested three different cover thicknesses (1/8” [3.125 mm], 3/16” [4.8 mm], and 1/4” [6.35 mm]) representing three skull thicknesses within the published range of human skull (2–16 mm) [40–43]. In addition, Young’s modulus of acrylic is 2.76–3.00 GPa, which is within the range of the human cranial bone tensile modulus of 0.45–10.0 GPa [43–47]. Cell culture media is a good simulant of cerebrospinal fluid, both with viscosity comparable to water [48, 49]. The cylinder was designed in Autodesk Fusion 360 and machined with a similar procedure as explained before for the mold Fig. 1C.
Primary Neuronal Culture
All procedures followed the guidelines established in the Guide for the Care and Use of Laboratory Animals and were approved by the Rutgers University Institutional Animal Care and Use Committee. Pregnant Sprague Dawley rats were obtained from Charles River Laboratories and then anesthetized with CO2 and euthanized using CO2 after embryos extraction. Rat brain cortices were isolated from E17 Sprague-Dawley rat embryos and stored in ice-cold HBSS containing Ca2+ and Mg2+. After rinsing with Ca2+free and Mg2+free HBSS, the cortices were mechanically disrupted by pipetting up and down (3–5 times). The media containing the cells was filtered with a nylon mesh filter with 100-µm pores and then a filter with 40-µm pores to remove large pieces of tissue. The remaining cortical cells were cultured on a poly-L-lysine (0.14 mg/mL)-coated custom-made polydimethylsiloxane [PDMS] wells (2,000,000 cells per well in 57-mm) in NeuroBasal media containing 2% B-27, 1% penicillin-streptomycin, and 0.4 mM L-glutamine at 37°C in a CO2 (5%) incubator. All methods here are reported according to ARRIVE guidelines.
Shockwave Exposure
Before adding cultured cells and media into the blast injury apparatus, the cylindrical container was autoclaved, and the acrylic cover sterilized using 70% ethanol. Inside a biological safety cabinet, PDMS neuronal cultures (day 10 in-vitro) were placed inside the cylindrical container, and the clear acrylic cover was then bolted to the container. Last, warm culture media (37°C) was injected into the apparatus through the Luer lock connections (Fig. 2c).
A compressed gas shock tube was used to replicate a free-field blast wave characterized by the Friedlander function [32, 34, 50]. The assembled blast apparatus with neuronal culture was quickly mounted inside the tube, facing the blast wave, and blasted at 70 kPa peak blast overpressure using helium gas, Fig. 2. Pressures were measured using high-frequency Tourmaline pressure transducers model 134A24 (1,000 psi maximum pressure, resonant frequency ≥ 1,500 kHz, 0.2 µs rise time, PCB Piezotronics, Depew, NY, USA). A series of pressure sensors were distributed along the length of the shock tube to measure pressure-time profiles including the incident shock wave at the location of the in vitro culture, Fig. 5. The apparatus pressure transducer was mounted though the side wall of the cylindrical housing and in contact with the medium surrounding the PDMS culture well, Fig. 2 (red arrow). This allowed for the measurement of the transmitted pressure wave form the incident shock wave and representative of the pressure profile presented to the normal cells. All data were recorded at 1.0 MHz sampling frequency, and the typical acquisition time ranged from 50 to 200 ms[32]. After blast, the apparatus was then disassembled under the sterile hood, media was changed and the PDMS culture wells with cells returned to the incubator for further examination.
Pressure Wave Analysis
All data were analyzed using MATLAB; the Fourier transform for the pressure wave signal was calculated using MATLAB’s fft function, the mean pressure using the mean function, and the pressure impulse using the trapz function. The average pressure wave amplitude, which is the arithmetic average of the absolute values of the deviations of the peak pressure from the mean pressure, was calculated using the following equations:
$$\:WA=\frac{1}{N}\sum\:_{i=1}^{N}\left|{x}_{i}-\mu\:\right|\:$$
$$\:\mu\:=\frac{1}{N}\sum\:_{i=1}^{N}{x}_{i}$$
where WA is the average pressure wave amplitude.
The incident blast pressure profiles from the experiments were analyzed. The mean maximum pressure was 15.79 psi ± 3.74, mean duration was 4.16 ms ± 0.64 and mean impulse was 17.82 psi.ms ± 3.57. Based on the measured mean incident blast wave duration of 4.16 ms; we limited our analysis of the apparatus pressure (intercranial pressure) to 4ms following the start of blast overpressure.
Cell Viability
Using a colloidal dye assay, we assessed cell viability by the cells’ ability to exclude trypan blue. The cells were incubated in 0.4% trypan blue solution for 30 minutes and then washed and counted using bright-field optics. Dead cells were distinguishable by their dark blue staining. Cells were injured on day 10 in vitro and viability counts were done 24 hours after injury.
Statistics
All the experiments included a minimum of three technical replicates, and all results are expressed as mean ± standard deviation. One-way ANOVAs was used to determine the differences between the control and experimental conditions, and a probability value of p < 0.05 was considered significant.