Isolation and cultivation of primary human T cells provide the foundation for in vitro and in vivo studies. It is well-established that upon activation and in vitro expansion, T cells differentiate into an effector-like phenotype, and that the choice of cytokine supplements strongly impacts those differentiation fates9. CAR T cells cultured with IL-7 and IL-15 demonstrated improved persistence and better anti-tumor activity in mouse models compared to T cells expanded with IL-229. Therefore, the choice of both activation reagents and cytokine supplements is important to yield T cells with the desired phenotype. We compared two activation reagents (CD3/28 beads and TransAct), that differentially influence T cell expansion kinetics, yield, and the CD4/CD8 ratio, over an expansion period of three weeks. In general, T cells expanded after CD3/28 bead activation showed a higher percentage of CD8+ and lower frequencies of CD4+ cells than after TransAct activation. As CD8⁺ T cells preferentially differentiate towards an effector-like TEMRA phenotype, reagent selection is a key variable that should match the goals of the experiment. In addition to phenotypic surface markers, the upregulation of activation markers yields information about the T cell state and effector functions. Both CD25 and CD69 are sensitive activation markers and are typically upregulated at early time-points after activation. They are commonly used to assess activation of T cells, but also other cell types, such as natural killer (NK) cells30,31,32. In contrast, the activation markers CD137 and CD154 showed lower expression in expanded T cells, highlighting their potential to assess specific upregulation in CAR T cells upon co-culture with target cells. Notably, when applying the activation marker panel to assess CAR T cell activity upon co-culture with target cells (i.e., tumor cells), a careful choice of activation markers is required to avoid high background expression of those markers on T cells even in the absence of target cells.
When working with primary T cells, one should be aware that their expansion and differentiation profiles are highly donor dependent. However, storage of the initial sample at 4 °C prior to T cell isolation and a short handling time overall improve the yield and the quality of isolated cells. Cell viability is influenced by the duration of freezing and thawing steps, since the freezing medium contains cryoprotectants such as dimethyl sulfoxide (DMSO). While DMSO is crucial for preserving cellular structures upon freezing, it is toxic to cells at room temperature. Therefore, fast handling and dilution of DMSO after thawing are required. When electroporating T cells, the cells are most sensitive after the electric pulse, which aims to make the cell wall permeable for mRNA. Handling the cells with care by avoiding additional shear stress and working with pre-warmed solutions may greatly increase cell recovery and viability. It can be beneficial to add a positive control mRNA, such as a CAR of known expression or a reporter protein such as GFP, when testing a new CAR construct. It is further recommended to include at least MOCK transfected cells (i.e., cells electroporated without mRNA) as negative control. For functional assays, mRNA encoding for a CAR directed against a different target may be used to assess CAR specific activation.
Since expression kinetics may depend on the mRNA sequence, assessing the kinetics individually is a valuable tool for choosing the ideal time point for the conduction of downstream assays. This transfection method is primarily intended as a rapid, easy way to screen multiple CAR constructs in parallel. Due to the short timeframe during which the CAR is expressed on the T cell surface, long-term assays cannot be conducted. However, from preliminary transfection experiments, one can determine the best CAR design to proceed to viral transduction, if desired.
Finally, antibodies or their conjugated fluorophores may be exchanged to fit the experimental setup. However, it is crucial to consider the respective excitation and emission spectra of the fluorophores to interpret the results reliably. Moreover, single staining with one antibody at a time can be conducted in preliminary experiments to assure correct compensation of a multi-color panel. While we did not require spectral compensation for the proposed antibody panel, it might be necessary to set up a compensation matrix when the panel is changed.
The presented IVT and electroporation protocol offers a simple and flexible alternative to viral transduction for introducing CAR constructs into primary human T cells. Because it relies entirely on RNA-based delivery, it can be performed in laboratories without access to BSL-2 infrastructure, significantly lowering the barrier for CAR T cell research. Although viral transduction is very efficient and is predominantly used in the CAR field, it is accompanied by safety concerns related to genomic integration, a potential cause of secondary malignancies, as well as labor and cost-intensive production33,34. Moreover, the transient nature of CAR expression makes this approach particularly suitable for rapid, parallel screening of multiple CAR designs35, allowing researchers to compare construct performance in a high-throughput manner. The drawback of this method is the limited time of CAR expression, which typically peaks around 6-12 h after electroporation22,24,35,36. With transient transfection, long-term cultures, such as repeated stimulation assays, cannot be performed due to CAR downregulation. However, we suggest identifying the most promising CAR construct(s) with mRNA electroporation before considering moving to stable expression systems with a limited number of candidates.
Electroporation of mRNA into primary cells is a versatile technology to express proteins such as antigens in different cell types, including PBMCs, T cells, B cells, NK cells, and dendritic cells37. Notably, another possibility for transient CAR delivery are lipid nanoparticles (LNPs)36,38, which allow the delivery of CAR-encoding mRNA or DNA into T cells without viral vectors and enables integration-free CAR expression. In contrast, the Sleeping Beauty transposon system39,40,41 achieves stable integration without the requirements of viral components. The most suitable choice of T cell transfection or transduction depends on the intended application and considerations for scalability and manufacturing. mRNA-based CAR T cells have been successfully used in preclinical and clinical studies against a variety of different entities, including hematological and solid malignancies and autoimmune diseases42,43,44. Transiently expressed CARs offer advantages compared to stably expressed CARs, since the limited surface expression can prevent or reduce side effects25.
In summary, this workflow provides a straightforward, step-by-step protocol for the isolation, activation, cultivation, analysis, and transfection of primary T cells to generate CAR T cells. It is simple to implement, does not require BSL-2 laboratory facilities, and can be readily integrated into laboratories equipped with standard molecular biology and cell culture facilities.