Photopolymerized Micro-Capillary Grids for Vascular Networks
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Solution Overview
Problem
Stereolithographic processes face challenges in achieving high axial resolution for fabricating micro-capillary devices with small internal diameters, leading to increased costs and decreased fabrication speed due to the need for high numerical aperture optics, which is not feasible for producing vascular networks with diameters as small as 5-20 μm.
Innovation Solution
The development of an optimized geometry for micro-capillary grids with vertically printed channels in an inverse U shape, connected at adjacent inlet and outlet openings, allowing for the use of low numerical aperture optics while maintaining high speed and reliability, using biocompatible photopolymerized hydrogels and reinforcing structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If high numerical aperture optics are used to achieve 5 μm axial resolution, then manufacturing precision is improved, but device cost increases and fabrication speed decreases
Solution Approach 1:
The patent changes the printing orientation from horizontal to vertical, exploiting the superior axial resolution of stereolithography in the vertical dimension. By printing channels vertically upwards from the base plate, the system achieves high resolution (5-20 μm internal diameter) using low numerical aperture optics, resolving the contradiction between manufacturing precision and device cost.
2Manufacturing precision
If high numerical aperture objectives are used, then axial resolution is improved, but fabrication speed decreases due to small field of view and small polymerization spot
Solution Approach 1:
The patent exploits the anisotropic resolution characteristics of stereolithography by orienting channels vertically, where the process naturally provides high resolution. This allows using low numerical aperture objectives with larger fields of view and faster polymerization spots, thereby maintaining high fabrication speed while achieving the required 5-20 μm channel dimensions.
3Adaptability or versatility
If channel diameter is reduced to 5-20 μm to mimic capillary vessels, then biological fidelity is improved, but fabrication reliability decreases due to material brittleness and flow blockage risks
Solution Approach 1:
The patent applies different wall thicknesses at different locations: thinner walls (5-15 μm) where biological fidelity is critical (channel interior) and thicker walls at structural support locations. This local differentiation allows achieving capillary-like dimensions for biological studies while maintaining fabrication reliability and preventing flow blockage.
Solution Approach 2:
The patent uses composite structures combining photopolymerized hydrogel channels with rigid support structures. The hydrogel provides biocompatibility and appropriate mechanical properties for tissue engineering, while the rigid support ensures structural integrity and prevents breakage of the fragile thin-walled channels during handling and operation.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enables the reliable fabrication of micro-capillary devices with internal diameters between 5-20 μm, mimicking vascular networks, while reducing costs and maintaining efficiency in the stereolithographic process, thereby supporting tissue growth and development.
Implementation Method 1
The device according to any one of statements 1 to 5, wherein the biocompatible liquid- and gas-permeable material is a photopolymerised hydrogel
Data Source
AI summary
The invention relates to devices for the culture of cellular aggregates, the device comprising abase plate (1) with inlet (21) and outlet (22) openings for delivery and removal of media wherein inlet and outlet openings are in fluidic connection with respectively inlet and outlet ports in the base plate, and comprising a plurality of channels of a biocompatible liquid- and gas-permeable material, wherein each of said channels is connected at one end to an inlet opening and at the other end to an outlet opening, characterized in that each channel extends at one end (31) upwards from the inlet opening, and extend at the other end upwards (32) from the outlet opening.