Precise Control of Pore Size in Hydrogel Scaffolds Fabricated by Mask Projection Lithography with Variable Optical Magnification

The field of tissue engineering requires versatile scaffold fabrication technologies capable of inducing cell proliferation and differentiation to promote functional tissue regeneration. Traditional fabrication methods face inherent trade-offs among production speed, resolution, and cost, which hinder their ability to replicate the intricate hierarchical structures of biological tissues. To address these challenges, we developed a mask projection photolithography system with variable optical magnification. This system allows for precise control of the microscale feature size in the final product using a single mask, by adjusting the optical magnification with interchangeable objective lenses and a relay lens. With this system, we successfully fabricated porous scaffolds with reproducible pore sizes ranging from 25 to 100 μm, exposing a Poly (ethylene glycol) diacrylate (PEGDA, Mn = 700) hydrogel precursor solution through a honeycomb-patterned mask for durations of just 3 to 10 seconds. The mask projection system presented in this study offers a powerful and efficient platform for creating the microstructures essential for various advanced biomedical applications, including tissue engineering, drug delivery, and organoid-on-a-chip, thanks to its unique combination of speed, precision, and cost-effectiveness.