Rapid prototyping of a multilayer microphysiological system for primary human intestinal epithelial culture

Here we report benchtop fabrication of multilayer thermoplastic organs-on-chips via laser cut and assembly of double sided adhesives. Biocompatibility was evaluated with Caco-2 cells and primary human intestinal organoids. Chips with Luer fluidic interfaces were economical ($2 per chip) and were fabricated in just hours without use of specialized bonding techniques. Compared with control static Transwell™ cultures, Caco-2 and organoids cultured on chips formed confluent monolayers expressing tight junctions with low permeability. Caco-2 cells on chip differentiated ~4 times faster compared to controls and produced mucus. To demonstrate the robustness of laser cut and assembly, we fabricated a dual membrane, tri-layer gut chip integrating 2D monolayers, 3D cell culture, and a basal flow chamber. As proof of concept, we co-cultured a human, differentiated monolayer and intact organoids in a chip with multi-layered contacting compartments. The epithelium exhibited 3D tissue structure and organoids formed in close proximity to the adjacent monolayer. The favorable features of thermoplastics, such as low gas and water vapor permeability, in addition to rapid, facile, and economical fabrication of multilayered devices, make laser cut and assembly an ideal fabrication technique for developing organs-on-chips and studying multicellular tissues.