Organ-on-a-Chip Fabrication using Dynamic Photomask

Organ-on-a-chip (OoC) technology is a powerful tool for creating physiologically relevant microscale models applicable to biomedical studies. Despite the advances in OoC technology, its fabrication method still primarily relies on soft lithography, which (1) lacks the adaptability to accommodate dynamic cell culture ( e.g. , spheroids and organoid culture) and (2) has a long design-to-prototype cycle that lowers its manufacturability. To overcome these challenges, we developed a system to fabricate OoC (consisting of microchannels and multiple cell types in a well-defined spatial arrangement) dynamically using a digital photomask aligned with a microchamber. Our approach used a pre-defined microfluidic chamber customized by xurography and cell-laden microfluidic channels photopatterned by a digital photomask; the entire design-to-prototype cycle was achieved within two hours. The versatility of our approach offered previously unattainable crucial features in the fabrication of OoC, including a gradual change in the height of the microchannels, and real-time modification of channel designs to trap live tissues ( e.g. , spheroids). In summary, this work highlights a versatile system to fabricate OoC that can accommodate various design requirements of microenvironments of specific organ tissues. We envision the effectiveness of our system for the rapid fabrication of OoC to contribute to the wide adoption of the technology for therapeutic screening and elucidation of disease mechanisms in both academic and industrial settings.