Layerless bioprinting via dynamic optical projection and uses thereof

Patent metadata

Field	Value
Publication number	US-10464307-B2
Application number	US-201515311135-A
Country	US
Kind code	B2
Filing date	May 20, 2015
Priority date	May 20, 2014
Publication date	Nov 5, 2019
Grant date	Nov 5, 2019

Abstract

A system and method for 3D microfabrication projects light capable of initiating photopolymerization toward a spatial light modulator that modulates light responsive to digital masks corresponding to layers of the structure. Projection optics focus the modulated light onto an optical plane within a photopolymerizable material supported on a stage. A computer controller causes the spatial light modulator to project a sequence of images corresponding to the digital masks while coordinating movement of the stage to move a position of the optical plane within the photopolymerizable material to sequentially project each image of the sequence to generate the structure by progressively photopolymerizing the photopolymerizable material.

First claim

The invention claimed is:

1. A system for 3D microfabrication of a structure, comprising:
a light source configured for projecting light within an optical path, the light source emitting light at a wavelength configured for initiating photopolymerization;
a stage configured to support one or more containers containing a photopolymerizable material, wherein the stage is configured for movement along at least one axis;
an optical assembly disposed within the optical path between the light source and the stage for projecting light toward an optical plane, the optical assembly comprising:
a spatial light modulator configured for modulating the light responsive to a set of digital masks corresponding to layers of the structure;
an optical tube having a window sealed at an end thereof, the window configured for immersion in the photopolymerizable material in the one or more containers to define a printing interface between the window and the photopolymerizable material, wherein the printing interface is substantially coincident with the optical plane;

and
a computer controller configured for generating control signals for:
controlling the spatial light modulator to project a sequence of images corresponding to the set of digital masks toward the optical plane; and
coordinating movement of the stage to move a position of the optical plane within the photopolymerizable material to sequentially project each image of the sequence to continuously generate the structure within the one or more containers by progressively photopolymerizing the photopolymerizable material along the at least one axis so that successive layers are polymerized on top of previously polymerized layers.

2. The system of claim 1 , wherein the spatial light modulator comprises a digital micromirror device.

3. The system of claim 1 , wherein the photopolymerizable material is a pre-polymer solution, and wherein at least a portion of the one or more containers contain different pre-polymer solutions.

4. The system of claim 1 , wherein the computer controller further executes steps for coordinating movement of the stage to control a volume of pre-polymer solution between the window and previously polymerized layers.

5. The system of claim 1 , wherein the one or more containers comprise wells within a multi-well plate.

6. The system of claim 1 , further comprising an electrode or a multi-electrode array disposed within the one or more containers.

7. The system of claim 1 , wherein the photopolymerizable material comprises a conductive polymer and at least a portion of the sequence of images corresponds to interconnecting structures aligned with one or more electrodes disposed within the one or more containers.

8. The system of claim 1 , further comprising a second light source disposed within the optical path, the second light source emitting light at a wavelength configured to stimulate a photo-active biological material.

9. The system of claim 1 , wherein at least a portion of the digital masks cause the spatial light modulator to generate subpatterns within selected layers of the structure.

10. A method for 3D microfabrication of a structure, comprising:
controlling the system of claim 1 using the computer controller to position the stage to immerse the window into the photopolymerizable material within the one or more containers and to project an image of the sequence of images toward the optical plane; and
simultaneously and continuously controlling, via a computer controller, the sequence of images and the stage movement to generate the structure by progressively photopolymerizing the photopolymerizable material along the at least one axis.

11. The method of claim 10 , wherein the one or more containers comprise wells within a multi-well plate.

12. The method of claim 10 , wherein at least of portion of the one or more containers contain different pre-polymer solutions.

13. The method of claim 10 , wherein the one or more containers have an electrode or a multi-electrode array disposed therein.

14. The method of claim 13 , wherein the photopolymerizable material comprises a conductive polymer and at least a portion of the sequence of patterns corresponds to interconnecting structures aligned with one or more electrodes.

15. The system of claim 1 , wherein the window is treated to inhibit adhesion of the photopolymerizable material.

16. The system of claim 1 , wherein the window is formed from a material selected from the group consisting of silica, sapphire, polydimethysiloxane (PDMS), transparent ceramic, and transparent plastic.

17. The system of claim 1 , wherein the photopolymerizable material comprises a photo-crosslinkable hydrogel selected from the group consisting of gelatin methacrylate [GelMA], methacrylated hyaluronic acid [MeHA] and polyethylene glycol diacrylate [PEGDA].

18. A system for microfabrication of a structure, comprising:
a spatial light modulator disposed within an optical path of a light source and configured for modulating light from the light source responsive to a set of digital masks corresponding to layers of the structure;
projection optics disposed within the optical path and configured to focus the modulated light to an optical plane;
a stage configured to support one or more containers containing a photopolymerizable material within the optical plane, wherein the stage is configured for movement along at least one axis;
an optical tube disposed within the optical path and having a window sealed at the end thereof, the window configured for immersion in the photopolymerizable material to define a printing interface between the window and the photopolymerizable material, wherein the printing interface is substantially coincident with the optical plane; and
a computer controller having software therein for generating control signals for:
controlling the spatial light modulator to project a sequence of images corresponding to the set of digital masks onto the optical plane; and
coordinating movement of the stage to move a position of the optical plane within the photopolymerizable material to sequentially project each image of the sequence to generate the structure within the one or more containers by progressively photopolymerizing the photopolymerizable material along the at least one axis so that successive layers are continuously polymerized on top of previously polymerized layers.

19. The system of claim 18 , wherein the spatial light modulator comprises a digital micromirror device.

20. The system of claim 18 , wherein the photopolymerizable material is a pre-polymer solution, and wherein at least a portion of the one or more containers contain different pre-polymer solutions.

21. The system of claim 18 , wherein computer controller is further operable for coordinating movement of the stage to determine a volume of pre-polymer solution between the window and previously polymerized layers.

22. The system of claim 18 , wherein the one or more containers comprise wells within a multi-well plate.

23. The system of claim 18 , wherein the one or more containers comprise wells within a multi-well plate.

24. The system of claim 18 , wherein the photopolymerizable material comprises a conductive polymer and at least a portion of the sequence of images corresponds to interconnecting structures aligned with one or more electrodes.

25. The system of claim 18 , wherein the photopolymerizable material comprises a p

Assignees

• Univ California

Inventors

• Chung Peter
• Qu Xin
• Zhang Aping
• Chen Shaochen

Classifications

• B29C64/277

  using multiple radiation means, e.g. micromirrors or multiple light-emitting diodes [LED] · CPC title

• B29C64/129

  characterised by the energy source therefor, e.g. by global irradiation combined with a mask · CPC title

• B29C64/386

  Data acquisition or data processing for additive manufacturing · CPC title

• B29C64/40

  Structures for supporting 3D objects during manufacture and intended to be sacrificed after completion thereof · CPC title

• G01N33/502

  for testing non-proliferative effects · CPC title