A Multi-layer, Self-aligning Hydrogel Micro-molding Process Offering a Fabrication Route to Perfusable 3D In-Vitro Microvasculature

The in-vitro fabrication of hierarchical biological systems such as human vasculature, which are made up of two or more cell types with intricate co-culture architectures, is by far one of the most complicated challenges that tissue engineers have faced. Here, we introduce a versatile method to create multi-layered, cell-laden hydrogel microstructures with coaxial geometries and heterogeneous mechanical and biological properties. The technique can be used to build in-vitro vascular networks that are fully embedded in hydrogels of physiologically realistic mechanical stiffness. Our technique produces free-standing 3D structures, eliminating rigid polymeric surfaces from the vicinity of cells and allowing layers of multiple cell types to be defined with tailored extracellular matrix (ECM) composition and stiffness, and in direct contact with each other. We demonstrate co-axial geometries with diameters ranging from 200–2000 μm and layer thicknesses as small as 50–200 µm in agarose– collagen (AC) composite hydrogels. Coaxial geometries with such fine feature sizes are beyond the capabilities of most bioprinting techniques. A potential application of such a structure is to simulate vascular networks in the brain with endothelial cells surrounded by multiple layers of pericytes and other glial cells. For this purpose, the composition and mechanical properties of the composite AC hydrogels have been optimized for cell viability and biological performance of endothelial and glial cell types in both 2D and 3D culture modes. Multi-layered vascular constructs with an endothelial layer surrounded by layers of glial cells have been fabricated. This prototype in-vitro model resembles vascular geometries and opens the way for complex multi-luminal blood vessels to be fabricated.