Vat Photopolymerization of Porous Scaffolds: Stabilization and Layer Thickness Control for Micron-Scale Accuracy

Vat Photopolymerization (VPP) holds much promise for producing biomaterial constructs such as porous scaffolds. However, achieving micron-scale pore dimensions with precision presents a challenge. This study offers an innovative approach to stabilize the silicone elastomer vat surface permitting micron-scale layer thickness accuracy to be maintained. Internal and surface contamination on the poly(dimethyl siloxane) (PDMS) vat surface were observed and effectively controlled with a pre-saturation methodology, and porous structures with cubical pores were then printed with varying layer thicknesses. These structures demonstrate the ability to achieve micrometric resolution and layer thicknesses as fine as 32 {micro}m. A scaffold suitable for in vivo implantation with 40 {micro}m cubical pores was successfully printed within 5 hours using a stabilized PDMS vat surface. Additionally, the methodologys adaptability to intricate non-linear edge porous structures underscores its versatility across X, Y, and Z-axis.