Vessel-on-a-Chip (VoC) technology, developed to replicate human vasculature in vitro, has advanced into two primary methodologies: endothelial cell (EC) coating and self-assembly. The EC coating approach enables precise engineering control over vessel...
Vessel-on-a-Chip (VoC) technology, developed to replicate human vasculature in vitro, has advanced into two primary methodologies: endothelial cell (EC) coating and self-assembly. The EC coating approach enables precise engineering control over vessel length and inlet/outlet interfaces, but depends on artificial boundaries that do not fully capture the physiological characteristics of the native extracellular matrix. In contrast, the self-assembly method produces highly physiological microvessels through cell-autonomous mechanisms, yet it remains limited in the ability to control vascular geometry and to achieve scalable vessel lengths.
This study introduces a novel hybrid platform that integrates the advantages of both EC coating and self-assembly methods to generate high-quality vasculature conforming to engineered geometries while preserving biological relevance. A central innovation is the development of precise engineering design rules based on Spontaneous Capillary Flow (SCF), advancing beyond the basic application of this phenomenon. By optimizing surface energy and geometric parameters to meet both flow and pinning requirements, a design rule was established that enables stable patterning of complex channel structures with widths as narrow as 250 µm, a resolution challenging to achieve with conventional 3D printing. Additionally, the incorporation of stepped bumps and post structures minimizes process errors during gel injection and ensures the spontaneous formation of perfusable ports following culture.
Co-culture of human umbilical vein endothelial cells (HUVECs) and lung fibroblasts (LFs) within this platform resulted in the formation of a perfusable, lumenized 3D microvascular network extending over 7 mm along the engineered guide rails. These results indicate that overcoming the geometric control limitations of traditional self-assembly and enabling the design of vessels into predetermined shapes allows for the simultaneous achievement of the scalable length and defined interfaces characteristic of the coating method, as well as the high physiological relevance associated with the self-assembly method.
In summary, this study presents a standardized VoC platform that replicates physiological diffusion distances while ensuring stable culture and perfusion, facilitated by SCF-based precision design rules. This platform is anticipated to serve as a reliable experimental tool for applications that require complex vascular architectures, including cancer research and drug screening.