Three-dimensional (3D) in vitro cell models are gaining popularity in cancer research compared to two-dimensional (2D) cell culture models because of their ability to more accurately represent the tissue microenvironment. This study introduces a novel approach for the fabrication of 3D cell culture models by combining modified melt-electrospinning technology and solution electrospinning to create 3D two-layer fibrous scaffolds. By manipulating electrospinning parameters (voltage 11–12 kV and feed rate 0.85–1.55 mg/min), we engineered poly (ε-caprolactone) (PCL) scaffolds with varying fiber diameters (8.9 ± 2.2 to 23.1 ± 3.4 μm) and pore sizes (32.7 ± 12.8 to 122.5 ± 21.1 μm). Non-thermal plasma (NTP) treatment at energy density of 0.23 J/cm2 enhanced surface hydrophilicity, evident in a significant reduction in water contact angles from 113 ± 0° to 64 ± 0°. A comprehensive set of characterization techniques, including X-ray diffraction (XRD), differential scanning calorimetry (DSC), and thermogravimetric analysis (TGA) confirmed that plasma treatment altered the surface wettability without compromising the scaffold's chemical stability or crystalline structure. Biological assays involving human breast cancer MDA-MB-231 cells and human glioblastoma U-87 MG cells demonstrated high cell viability, indicating biocompatibility of the scaffolds. A pronounced difference in proliferation patterns was noted between MDA-MB-231 and U-87 MG, with the latter fully utilizing voids for the formation of cell aggregates, especially in the “fine” scaffold, indicating the dependence of cell behavior on scaffold architecture, which must be adjusted according to the modelled system and duration. Furthermore, investigation of the therapeutic efficacy of doxorubicin revealed a distinct drug response in 3D cultures, EC50 values of doxorubicin in 3D culture was approximately twice higher compared to 2D. These findings underscore the potential of tailored PCL scaffolds to create more physiologically relevant models for cancer research, tissue engineering, and drug screening applications, highlighting the necessity for careful consideration of scaffold design to achieve the desired in vitro model.
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