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In this work, we present a new 3D printing technique that enables the realization of native digital micromirror device (DMD) resolution in negative features of a 3D printed part without improving 3D printer hardware and demonstrate the fabrication of fully integrated, biocompatible isoporous membranes with pore sizes as small as 7 µm. We utilize this technique to construct a microfluidic device that mimics an established organ-on-a-chip configuration, including an integrated isoporous membrane. Two cell populations are seeded on either side of the membrane and imaged as a proof of concept for other organ-on-a-chip applications. These 3D printed isoporous membranes can be leveraged for a wide variety of other mechanical and biological applications, creating new possibilities for seamlessly integrated, 3D printed microfluidic devices. [ABSTRACT FROM AUTHOR]

Organs-on-a-chip, or OoCs, are microfluidic tissue culture devices with micro-scaled architectures that repeatedly achieve biomimicry of biological phenomena. They are well positioned to become the primary pre-clinical testing modality as they possess high translational value. Current methods of fabrication have facilitated the development of many custom OoCs that have generated promising results. However, the reliance on microfabrication and soft lithographic fabrication techniques has limited their prototyping turnover rate and scalability. Additive manufacturing, known commonly as 3D printing, shows promise to expedite this prototyping process, while also making fabrication easier and more reproducible. We briefly introduce common 3D printing modalities before identifying two sub-types of vat photopolymerization – stereolithography (SLA) and digital light processing (DLP) – as the most advantageous fabrication methods for the future of OoC development. We then outline the motivations for shifting to 3D printing, the requirements for 3D printed OoCs to be competitive with the current state of the art, and several considerations for achieving successful 3D printed OoC devices touching on design and fabrication techniques, including a survey of commercial and custom 3D printers and resins. In all, we aim to form a guide for the end-user to facilitate the in-house generation of 3D printed OoCs, along with the future translation of these important devices. [ABSTRACT FROM AUTHOR]