Fabrication of an Anatomically Realistic Intestinal Phantom with Villous Microstructure

The accurate evaluation of gastrointestinal (GI) diseases such as celiac disease (CeD) relies on the assessment of villous architecture, yet progress in imaging-based diagnostics, particularly video capsule endoscopy (VCE), is constrained by the absence of anatomically realistic and reproducible physical models of the intestinal mucosa. Existing benchtop phantoms typically reproduce gross luminal curvature but fail to capture the sub-millimeter villous microstructure, the optical scattering behavior, and the luminal folding of native mucosa that together shape its endoscopic appearance. We developed a modular fabrication framework for an anatomically realistic small intestinal phantom with controlled villous microstructure. High-resolution drop-on-demand photopolymer material jetting was used to print discrete patches of villous-like micropillar arrays with tunable height, diameter, and spacing parameterized from histological data spanning Marsh 0 to 3c classifications. The printed patches were then dyed for mucosal-color realism, bonded onto a polyester–spandex substrate, rolled into a continuous tube, and shaped with adjustable retainer rings to introduce luminal folds. Optical microscopy confirmed dimensional fidelity within ±10% of design values with patch-to-patch variation below 7%, and VCE imaging of healthy and atrophic configurations achieved structural similarity (SSIM) values of 0.625 and 0.761 against clinical mucosal imagery. This reproducible platform supports VCE device validation, imaging dataset generation, and clinician training in gastrointestinal imaging.