Published online by Cambridge University Press: 01 February 2011
Microfabrication and soft lithographic techniques are combined to develop three-dimensional (3D) polydimethylsiloxane (PDMS) scaffolds comprising multiple levels of meandering pore geometry textured with 10 μm posts. Both micro-architecture and surface micro-textures have been shown to selectively stimulate cell and tissue behavior. To achieve a 3D scaffold with precise micro-architecture and surface micro-textures, 100 μm thick PDMS films were manufactured using a stacking technique to realize a 66% porous 3D structure with 200 × 400 μm horizontal through holes, 300 μm diameter vertical through holes and 71% surface coverage with 10 μm diameter and 10 μm high posts. Each PDMS porous film level was manufactured by the dual-sided molding of uncured PDMS between a three level SU-8 photoresist mold (of 200, 10, and 100 μm thick features) and a PDMS mold with 10 μm deep micro-textures. Dual-sided molding was achieved using a custom motion control mechanical jig that allowed relative mold alignment to within ∼ ±10 μm.