Fabrication of Complex 3D Micro-Scale Scaffolds and Drug Delivery Devices using Dynamic Mask Projection Microstereolithography

Microstereolithography (μSL) technology can fabricate three-dimensional (3D) tissue engineered scaffolds with controlled biochemical and mechanical micro-architectures. A μSL system for tissue engineering was developed using a Digital Micromirror Device (DMDTM) for dynamic pattern generation and an ultraviolet (UV) lamp filtered at 365 nm for crosslinking the photoreactive polymer solution. The μSL system was designed with x-y resolution of ~2 μm and a vertical (z) resolution of ~1 μm. To demonstrate the use of μSL in tissue engineering, poly(propylene fumarate) (PPF) was synthesized with a molecular weight of ~1200 Da. The viscosity of the PPF was reduced to ~150 cP (at 50 o C) by mixing with diethyl fumarate (DEF) in the ratio of 7:3 (w/w). Finally, ~2 % (w/w) of (bis(2,4,6- trimethylbenzoyl) phenylphosphine oxide (BAPO) was added to the solution to serve as a photoinitiator. Cure depth experiments were performed to determine the curing characteristics of the synthesized PPF, and the resulting system and photopolymer were used to construct a variety of 3D porous scaffolds with interconnected pores between 100 and 150 μm and a micro-needle array with height of ~800 μm and individual tip diameters of ~20 μm. SEM and microscope images of the micro-architectures illustrate that the developed μSL system is a promising technology for producing biodegradable and biocompatible microstructures.