Advanced Materials Technologies

Despite technological advances, the fabrication of multiscale, multi-material, and topologically complex 3D structures using soft hydrogel bioinks remains a challenge due to the inherent trade-offs between print size/resolution, bioink properties, and design complexity. In this work, we combine additive (macroscale) digital light projection (DLP) mode with subtractive (microscale) two-photon ablation (TPA) mode with multi-material exchange capability. We identify ideal hydrogel bioink formulations that are compatible with both DLP and TPA modes of processing. Technical challenges related to multimodal fabrication such as alignment of multiscale topologies to facilitate seamless media perfusion, soft-hard multi-material printing to facilitate handling of mechanically weak hydrogel constructs, and hydrogel swelling during printing, were resolved. To highlight the novelty of this hybrid platform, we fabricated centimeter-scale bioink constructs with embedded microscale perfusable topologies that cannot be achieved by isolated use of either DLP or TPA modes. This includes simpler microfluidic chips with independently perfusable microchannels to more complex 3D constructs with embedded, multiscale, perfusable dual-fluidic circuits that mimic the alveoli-capillary interface, or microfluidic chips with endothelialized microchannels. The unique ability of this multimodal platform to mimic in vivo-like multiscale complexities can be potentially used to develop next-generation organ-on-chips.

Elastic porous membranes are essential components of mechanically active organ-on-a-chip and microphysiological system (MPS) platforms, where cyclic strain is required to recapitulate physiologically relevant tissue mechanics. However, existing fabrication methods are often difficult to reproduce, low throughput, or dependent on specialized infrastructure, limiting their adoption across laboratories. Many protocols also lack quality control steps for ensuring device assembling and reproducibility. In this paper, we present a robust and accessible fabrication and quality control workflow for the consistent production of elastic porous PDMS membranes. The method uses commercially available heat presses, release liners, and pre-patterned membrane wafers to enable rapid membrane molding. We describe a quality control framework, including visual verification of porous regions and wettability testing for surface activation, to ensure irreversible PDMS bonding and reliable device assembly. Together, this workflow improves fabrication yield, reduces device failure, and supports reproducible implementation of elastic porous membrane in organ-on-a-chip applications.

Three-dimensional (3D) in vitro tumor models are critical for studying transport-limited drug efficacy in solid tumors; however, many existing platforms are technically complex and remain difficult to access. Stacked paper-based tumor models ("cells-in-gel-in-paper", CiGiP) address this challenge by enabling formation of diffusion-limited microenvironments while allowing direct access to cells from distinct tissue depths. Nevertheless, current CiGiP implementations rely on wax or hydrophobic barrier patterning of paper, which has become increasingly inaccessible. Here, we present a wax-printing-free approach for fabricating stacked paper-supported 3D tumor tissues using a simple 3D-printed press-fit enclosure that holds circular paper layers snugly together, thereby enforcing one-dimensional transport without lateral leakage. Using MDA-MB-231 breast cancer cells embedded in Matrigel, we demonstrate the formation of nutrient-limited microenvironments across the tissue depth, as evidenced by layer-dependent cell viability. The platform enables direct quantification of spatial and temporal drug responses, demonstrated using doxorubicin and paclitaxel, both individually and in combination. Layer-dependent cytotoxicity was measured, and combination treatment analysis revealed antagonistic interactions consistent with prior reports. By eliminating the need for hydrophobic patterning, this approach substantially lowers the technical barriers to constructing stacked paper tumor models and is expected to facilitate broader adoption of paper-supported 3D tissues for drug screening and mechanistic studies. Graphical Abstract O_FIG O_LINKSMALLFIG WIDTH=200 HEIGHT=77 SRC="FIGDIR/small/705119v1_ufig1.gif" ALT="Figure 1"> View larger version (23K): org.highwire.dtl.DTLVardef@55f56aorg.highwire.dtl.DTLVardef@1633288org.highwire.dtl.DTLVardef@18aae9eorg.highwire.dtl.DTLVardef@1ce1532_HPS_FORMAT_FIGEXP M_FIG C_FIG

Under acidic conditions, polycationic polymer coatings function as protective immobilization supports through protonation-mediated local pH buffering. However, it remains unclear how polymer support design parameters, such as film thickness and charge density, govern that vital protonation process. Leveraging the precise control of film thickness and copolymer composition enabled by initiated chemical vapor deposition (iCVD), we systematically investigated how these parameters govern the protonation behavior of poly[glycidyl methacrylate-co-2-(dimethylamino)ethyl methacrylate] (pGD) thin films and, in turn, the activity of immobilized {beta}-galactosidase (LacZ). Infrared spectroscopy suggests that proton penetration was capped at a depth of [~]250 nm in pGD with 65% DMAEMA, limiting the polycationic thickness in pGD films thicker than this value. Consistent with this limit, immobilized LacZ activity under acidic stress (pH 4) increased with protonated thickness up to [~]250 nm and then plateaued. Raising the polycationic monomer content from 25 to 65 mol% increased LacZ activity at pH 4 by up to 83%, consistent with a higher positive charge density providing stronger local pH buffering. To test whether this behavior depends on immobilization sites, we evaluated two approaches: random immobilization (via amine-epoxy ring-opening reactions) and site-directed immobilization (via SpyCatcher/SpyTag binding). Directed immobilization preserved higher LacZ activity than random immobilization, but the protonation-dependent protection trend remained consistent for both strategies. These findings establish protonation depth and charge density as tunable design parameters for polycationic immobilization supports that stabilize enzymes under acidic conditions.

Curvature provides essential mechanical cues for epithelial cells, playing a key role in cell differentiation and morphology. Repeatable manufacture of precisely controlled curvature in soft hydrogel materials is therefore essential to study epithelial mechanobiology and function. Multiphoton (MP) based biofabrication holds promise due to its high resolution and three-dimensional design flexibility. Here, we leverage MPs advantages while increasing print speed to develop two complementary tools based on replica molding and multiphoton ablation. These can provide scalable hydrogel curvatures with tunable surface properties relevant for epithelial tissue engineering. In replica molding, MP prints are transferred into PDMS used to pattern centimeter scale arrays in hydrogels. In multiphoton ablation, hydrogels are locally degraded to generate precisely controlled curvatures and surface topography. With both methods, we repeatably guide epithelial cells into alveolar and duct-like shapes. Concave alveolar-like surfaces are shown to enhance the formation of thicker epithelial layers. We observe that surface properties, controlled by both tools, could enhance cytoskeletal organization. Using these biofabrication techniques, individual effects of curvature, surface properties, hydrogel composition, and bulk stiffness on epithelial cells can be studied. Both approaches offer high curvature control and throughput, providing a viable alternative to traditional 3D culture and other printing methods.

Although biohybrid robots offer the potential for soft, adaptive actuation by harnessing living muscle, practical operation in cell culture environments is often limited by the requirement of immersed leads or cumbersome stimulation equipment. Here, we present a thin, miniaturized, wireless bioelectronic stimulator that can electrically drive biohybrid robots while maintaining stability in aqueous cell culture media. Built on a 50-{micro}m liquid crystal polymer (LCP) substrate, the device integrates a planar receiving coil, interconnects, a diode-based rectifier, and a tank capacitor. This enables the device to convert an approximately 4.9-MHz radio-frequency (RF) input into pulsed direct current (DC), which is delivered through integrated stimulation electrodes. The stimulator has a footprint of [~]23 mm2 and a total thickness and mass of [~]100 {micro}m and [~]7 mg, respectively. We integrated the stimulator with a nanopatterned carbon nanotube (CNT)/gelatin hydrogel fin seeded with human induced pluripotent stem cell-derived cardiomyocytes (iPSC-CMs) to generate propulsion through fin flapping. By optimizing the thickness of the polydimethylsiloxane (PDMS) encapsulation layer, the density was tuned, and the robot remained freely floating and retained shape integrity during operation. This produced autonomous forward locomotion of [~]70 {micro}m/s. The stimulator generated distance-dependent output voltage pulses of [~]2-6 V and reliably synchronized fin flapping rates of up to 2 Hz without an observable loss of cell attachment or sarcomeric organization. Together, these results establish a compact, media-compatible, wireless, bioelectronic interface suitable for closed-system biohybrid robotics.

Organ-on-chip (OoC) platforms are increasingly adopted for predictive in vitro testing. However, most remain limited by soft-lithography-derived 2.5D microfluidic architectures and non-physiological rigid materials, or bioprinting approaches that require complex and failure-prone post-fabrication assembly. Here, we present a versatile approach that integrates tomographic volumetric additive manufacturing (TVAM) directly within preassembled microfluidic chips, enabling rapid, contactless fabrication of freeform 3D OoCs. Leveraging our open-source optical simulation framework, Dr.TVAM, we perform TVAM in custom-designed chips, eliminating post-printing manual assembly steps that commonly lead to leakage, contamination, and poor reproducibility. This strategy, termed TVAM-in-a-chip, supports the generation of diverse 3D channel architectures in multiple biocompatible photoresins spanning a wide range of chemistries and mechanical properties, including cell-laden formulations. We demonstrate multi-channel designs, compatibility with confocal imaging, and dynamic culture of epithelial and endothelial models. Overall, TVAM-in-a-chip overcomes key limitations of current OoC technologies and paves the way for a new generation of scalable, biomimetic 3D platforms for advanced in vitro modeling.

Organ chips offer a disruptive innovation to study human diseases with tissue-specific resolution within a predictable and tunable in vitro environment. However, these platform technologies have for the most part failed to translate to broad use in the private sector due to a lack of high-throughput, user-friendly platforms. Here we present an automated high-throughput organ chip seeded with iPSC-derived cardiomyocytes transduced with GCaMP6f and interface with translational technologies to bridge the current academia-industry gap. Cardiomyocytes were seeded on-chip fully hands-free using an entry-level fluid handling robot to significantly reduce user handling requirements. Pipette interfaces were paramount to facilitating seeding and feeding through improved tolerances for establishing a functional connection to dispense and collect small fluidic volumes. Following successful seeding, GCaMP6f activity on-chip was monitored with our automated, non-invasive fiber-optic sensing platform. We show a significant decrease in cardiomyocyte beat rate in response to decreased ambient culture temperature using data collected with our optical sensing platform. This study provides a potential translational blueprint for academia-industry partnership toward broad adoption of organ chip technology in drug development and disease modeling.

Thermoplastic polyesters are widely used in commodity and high-performance applications due to their tunable and exceptional properties, versatile performance, and increasing relevance in sustainable materials. Integrating biological functionality into these polymers offers a promising route to enhance performance and end-of-life behavior beyond what conventional additives can achieve. Here, we report the generalization of an embedded spore-based engineered living material concept to three representative thermoplastic polyesters; polycaprolactone (PCL), polylactic acid (PLA), and poly(butylene adipate-co-terephthalate) (PBAT). Heat-shock-tolerized Bacillus subtilis spores were compounded with each polyester as a living biofiller via hot melt extrusion. The resulting biocomposite polyesters retained high spore viability (>90%) after extrusion and exhibited improved mechanical performance (up to 41% toughness improvement compared to neat polymers). End-of-life behavior was evaluated in a microbially-limited composting environment, where spore-containing PCL exhibited nearly complete disintegration within five months, corresponding to a [~]7-fold increase in degradation kinetics relative to neat PCL. Finally, 3D printing of biocomposite PCL was demonstrated through fused deposition modeling and direct ink writing methodologies. Together, this work demonstrated the successful extension of spore-based engineered living materials from thermoplastic polyurethane to multiple thermoplastic polyesters. Graphical Abstract O_FIG O_LINKSMALLFIG WIDTH=200 HEIGHT=86 SRC="FIGDIR/small/707801v2_ufig1.gif" ALT="Figure 1"> View larger version (26K): org.highwire.dtl.DTLVardef@4eaafaorg.highwire.dtl.DTLVardef@bb17c2org.highwire.dtl.DTLVardef@114e4ceorg.highwire.dtl.DTLVardef@b9bd0c_HPS_FORMAT_FIGEXP M_FIG C_FIG

Pancreatic ductal organoids (PDOs) generated from human induced pluripotent stem cells (iPSCs) can be used to model pancreatic diseases and to conduct drug screening/testing. However, current protocols for generating PDOs rely heavily on tumor-derived Matrigel, which has been shown to upregulate oncogenes. Furthermore, Matrigel has undefined composition and weak mechanical properties that hamper mechanistic studies of cell-material interactions. In this study, we explore photo-clickable decellularized small intestine submucosa-norbornene (dSIS-NB) hydrogels as a Matrigel replacement for generating human iPSC-derived PDOs. To achieve this, pancreatic progenitors (PP) were first differentiated in conventional two-dimensional (2D) culture, aggregated into spheroids, then encapsulated and differentiated within dSIS-NB hydrogels with tunable stiffness. The differentiated organoids were analyzed by morphology, expression of key pancreatic ductal markers, and single-cell RNA sequencing (scRNA-seq). Post-differentiation, PDOs generated in stiffer photo-clickable dSIS-NB hydrogels (shear moduli [~]2.5 kPa) maintained ductal epithelial phenotype and exhibited pronounced forskolin-induced swelling. In contrast, differentiation of PP spheroids in softer dSIS-NB gels (shear moduli [~]0.9 kPa) and Matrigel resulted in a persistent mesenchymal phenotype and failed to generate functional PDOs. Finally, scRNA-seq results revealed that stiffer dSIS-NB hydrogels strongly biased ductal cell differentiation, yielding greater than 97% ductal progeny.

Neurotechnology is being explored for restoring sensorimotor functions after paralysis or amputation, which requires peripheral nerve interfaces that are selective, bidirectional, and chronically stable. Reduced graphene oxide (rGO)-based microelectrodes offer low impedance and a high charge-injection limit; however, long-term in vivo performance has been limited by the durability of encapsulation. Here, we introduce a 10 {micro}m-thick transverse intrafascicular multichannel electrode (TIME) with a hybrid polyimide-Al2O3 encapsulation engineered to improve fabrication yield, electrode-to-electrode uniformity, and device stability. In vitro, devices maintained near-ideal capacitive behaviour after accelerated ageing (3 months in PBS at 57 {degrees}C) and sustained 109 biphasic stimulation pulses without detectable electrochemical degradation. In vivo, the arrays recorded compound nerve action potentials after one month and enabled selective activation of distinct peripheral nerve fibres with comparatively low current thresholds during four months of follow-up, remaining below the device maximum injectable current. Together, these results demonstrate that combining graphene microelectrodes with a thin hybrid encapsulation improves chronic reliability of intraneural thin-film interfaces and helps to close the gap between laboratory prototypes and clinically relevant neuroprosthetic systems.

Neuroelectronic thin-film implants hold promise for advancing fundamental understanding of the peripheral nervous system and offer potential for targeted treatments using specific stimulation. However, challenges in establishing robust and durable connections to soft and flexible implants limit their widespread adoption and long-term utility. Here, we present a novel method for integrating rigid electrical components, such as a standard USB-C connector, directly into a printed stretchable self-folding cuff electrode for chronic peripheral nerve interfacing. Our multi-material printing approach provides a gradual stiffness transition, effectively mitigating common failure points associated with mechanical stress at soft-rigid boundary. We demonstrate the integration of a wireless stimulation circuit and a robust USB-C implantable port, offering a plug- and-play solution for stable chronic electrophysiology experiments. Chronic implant studies in free-running locusts with USB-C connectors show reliable nerve recordings, capturing behavioral differences. The concept is further validated as a transcutaneous implanted port in rats for vagus nerve recordings. This work addresses a critical bottleneck in neurotechnology by enabling robust connectivity for implanted devices, which is essential for advancing peripheral nervous electrophysiology experiments in freely moving small vertebrates and insects.

Pluripotent stem cells represent a potentially unlimited cell source for the fabrication of human bioartificial tissues to study and treat degenerative conditions such as type 1 diabetes. Alginate is widely used for mammalian cell immobilization and the primary hydrogel studied for pancreatic islet encapsulation. Rheological properties of alginate solutions or fully gelled forms are unsuitable as support matrix for embedded 3D printing. We describe partially gelled self-healing alginate formulations tuned for embedded 3D printing. Perfusable multi-plane hierarchical networks branching into 10 parallel channels, obtained by 3D printing of Pluronic F127 into the alginate support, show high fidelity to computer-assisted models. Therapeutic {beta}-cell doses (40x106 cells/mL) within centimeter-thick perfusable constructs remained viable for at least 1 week of culture under flow, with rapid insulin secretion detected upon glucose challenges. Stem cell-derived islet clusters cultured in 5-channel contructs for 25 days differentiated towards functional insulin-expressing cells. We describe a novel approach to generate cm-scale perfusable endocrine pancreatic constructs using sacrificial embedded 3D printing into alginate. This approach offers an adaptable platform to engineer perfusable cm-scale functional endocrine pancreatic tissues and potentially other vascularized bioartificial tissues.

Miniaturized neural interfaces for research, diagnostics, and neuromodulation therapies require electrode materials that maintain low impedance and high charge injection capacity as device dimensions shrink to ensure high-quality recordings and safe stimulation. Conventional interfaces rely on metals like platinum (Pt), which are limited by intrinsically high impedance and low charge transfer capacity, reducing their performance in sub-100 {micro}m applications. Ti3C2Tx MXene has emerged as a promising alternative for high-density recording and stimulation interfaces, though the fundamental charge transfer mechanisms governing its performance remain poorly understood. This study evaluates Ti3C2Tx MXene microelectrodes across a range of diameters (25 - 500 {micro}m) and systematically elucidates the mechanisms governing their recording and stimulation capabilities. Electrochemical impedance spectroscopy, cyclic voltammetry, and voltage transient measurements - supported by equivalent-circuit modeling - revealed enhanced recording and stimulation capabilities of the MXene microelectrodes over size-matched Pt microelectrodes, attributed to reduced charge-transfer resistance and increased double-layer capacitance. Finally, varying the volume and concentration of the spray-coated Ti3C2Tx films showed that increased MXene concentration and volume enhanced performance by creating thicker, rougher interfaces. Together, these results establish Ti3C2Tx MXene as a promising electrode material with exceptional performance at the microscale.

Currently in vitro models of microvascular biology rely on self-assembly of vascular cells in compatible gels. However, the stochastic nature of this process results in large variations in lumen sizes, perfusion continuity, and shear stresses making systematic and reproducible analysis challenging. Here, we report a new technology to generate artificial capillaries on a chip with custom control over lumen sizes and architectures using a combination of femtosecond laser cavitation and collagen casting within multi-chambered microfluidic chips. The design allows seeding of endothelial cells within capillary-sized microchannels and seeding of stromal cells within top-open silos, with independent control over seeding sequence and media compositions. Results show that endothelialized microchannels, coined as artificial capillaries, exhibit excellent barrier function with reproducible control over lumen sizes ({phi}=8-35{micro}m) and their architectures (straight, curvatures, tapered, branched). The physical flow parameters measured across the lumen (namely, flow shear) and at the channel outlets (flow velocities) have been validated against high-fidelity numerical assessments from the Large Eddy Simulation scheme within the digitized versions of the microchannels. The experiment-computation compatibility enabled us to predict changes in regional velocity and wall shear stresses within artificial capillaries, for various capillary architectures. We also show that in situ editing of artificial capillaries in the form of adding new branches or adding occlusions is possible. Lastly, we developed a co-culture model which enables the study of stromal cells with artificial capillaries using conventional imaging methods. We envision that acellular chips with two seeding ports can be readily shipped worldwide and could potentially be adopted as a new technology to study microvascular biology in a reproducible manner.

In vitro models are increasingly critical for interrogating cancer biology and therapeutic response, however, accurately recapitulating the tumor microenvironment (TME) remains a persistent challenge, particularly in head and neck cancers (HNC) characterized by complex cell-matrix interactions and heterogeneity. Current models often lack independent tunability of biochemical and biophysical cues, limiting systematic investigation of microenvironmental cues in a high-throughput format. Here, we establish a 3D droplet-based bioprinting platform for the fabrication of customizable in vitro TME models using poly(ethylene glycol) (PEG) hydrogels. Human HNC cell lines (FaDu and 2A3) with differing HPV statuses were bioprinted into PEG matrices spanning physiologically relevant stiffnesses (0.7-4.8 kPa) and compositions, including non-functionalized PEG and peptide-functionalized PEG (PEGfnc: RGD, YIGSR, CNYYSNS) and cultured for 7 days. Cluster growth, cell viability, and cluster morphology were assessed across multiple time points, matrix compositions, and matrix stiffnesses. Proliferation and endpoint phenotype expression were visualized using confocal microscopy through immunofluorescence. Results indicated enhanced cell viability in PEGfnc matrices, compared to non-functionalized matrices, while effect of matrix stiffness was less prominent. Median cluster size reached 40-50 m by day 7, and linear mixed-effects modeling identified how changes in cluster surface area, volume, and tumoroid complexity varied with cell type, matrix, and stiffness. By decoupling and systematically varying key TME parameters, this approach provides a robust and scalable framework for dissecting tumor-matrix interactions and advancing physiologically relevant in vitro models for cancer research and therapeutic screening.

Engineering functional tissue constructs requires not only replicating their 3D architecture but also capturing their dynamic biochemical and mechanical environments. While 3D bioprinting technologies enable spatial control over cell and biomaterial deposition, post-fabrication modulation of material properties remains limited. Photografting approaches allow for spatiotemporal functionalization of certain 3D matrices by chemically binding bioactive factors onto spatially determined regions of a material, but current methods often rely on specialized chemistries with narrow material compatibility. Here, we introduce AddGraft, a biocompatible, off-the-shelf additive designed for semi-orthogonal thiol-ene photografting in vinyl-functionalized hydrogels. AddGraft, a heterobifunctional polyethylene glycol, carries an acrylate moiety for network incorporation during photocrosslinking and a norbornene group for post-crosslinking functionalization. AddGraft integrates into the polymer network during gel crosslinking without altering bulk mechanics, enabling precise modification at any time post-fabrication. We demonstrate compatibility with multiple acrylated biomaterial platforms and light-based volumetric photopatterning technology. Photopatterning achieves high spatial resolution and gradient formation in 3D, while grafting of multi-thiolated crosslinkers allows localized stiffening of hydrogels. Encapsulated human mesenchymal stromal cells exhibit high viability and undergo morphological changes in response to the dynamic tuning of their microenvironment. By decoupling structural and functional roles, AddGraft enables on-demand spatial and temporal control over hydrogel properties. This approach expands the biofabrication toolkit for engineering cell-instructive, 4D tissue environments with translational relevance in regenerative medicine.

The brains complex network relies on both electrical and chemical signaling to support its physiological and cognitive functions. To fully understand neural circuit dynamics and their dysfunctions, it is crucial to simultaneously detect neurotransmitters and modulators alongside electrophysiological signals. The striatal dopamine circuits are integral to neurological processes such as movement, reward, learning, and circadian rhythm regulation, making it highly desirable to monitor both neural activity and dopamine (DA) levels in freely behaving animals. One promising approach involves the implantation of multimodal microelectrode arrays (MEAs). However, chronic electrochemical sensing of DA in freely moving animals faces significant challenges, including biofouling of sensing electrodes and the instability of Ag/AgCl reference electrodes. In this study, we developed two complementary strategies--surface grafting and photo crosslinking--to coat the MEA and implanted Ag/AgCl reference electrodes, respectively, with zwitterionic poly(sulfobetaine methacrylate) (PSB). The surface-grafted thin PSB coating effectively inhibits protein fouling and inflammatory responses to the MEA, while the PSB hydrogel protects the Ag/AgCl electrodes from delamination in vivo, ensuring a stable reference potential. By coating both the Ag/AgCl reference electrodes and flexible polyimide MEAs with PSB and PEDOT/CNT, we achieved stable DA detection and electrophysiological recordings in freely moving mice over a four-week period. Weekly electrochemical impedance spectroscopy confirmed the long-term stability of the implanted electrodes. Our method enables multidimensional analysis of behavioral patterns, electrophysiological activity, and DA dynamics, providing a comprehensive approach for neuroscience research. This work advances neurochemical and electrophysiological methodologies by offering reliable tools for longitudinal investigations of brain function in freely behaving animals.

Microphysiological systems (MPS) are essential for modeling tissue barriers, yet integrating electrical readouts often requires permanently sealed microfluidic architectures that limit access to open-well (direct-access) workflows used in bioscience laboratories. To resolve this issue, we present a modular approach in which functional components are added and removed from a standard MPS core using a magnetic interface. This design preserves compatibility with established open-well protocols for seeding and downstream analysis, while microfluidic perfusion or electrical sensing capabilities are added only when needed. We demonstrate this approach with an impedance-sensing module that enables continuous impedance measurements to assess barrier function. By fitting spectra to an equivalent circuit model, we quantify junctional and non-junctional electrical contributions to barrier integrity over time, alongside conventional single-frequency TEER, and complementary permeability and imaging readouts. We apply this platform across three representative use cases, including LPS-induced disruption, shear stress-mediated strengthening, and compatibility with barrier models formed above a 3D hydrogel matrix.

Neurons in the brain are organized and connected into complex networks in which electrochemical signaling forms the basis for all brain function. Cortical neuronal net-works are arranged in distinct modular, layered, and hierarchical structures, underlying its diverse functions such as learning, memory, or vision. Modern biotechnology has enabled an array of techniques to culture human neural cells, ranging from discreet co-cultures to complex developmental organoids, but all of which almost exclusively form unstructured and hypersynchronous networks. Overcoming this and capturing the functional and anatomical properties of the brain in vitro has proven to be a great challenge. Current techniques for guiding neuronal connectivity in vitro is often limited to a small fraction of the total population of neural cells, leaving most of the culture effectively unguided. To provide large-scale guidance of neurons in culture, we developed a microtunnel device which allows large-scale cell entry through an array of perforations, and guides neuronal network formation through a series of tunnels. Human neural stem cells capable of forming extensive neuronal projections were used to investigate several different microtunnel designs. One particularity noteworthy design which produced predominantly unidirectional growth was used to successfully validate its effect on propagation of neural activity on microelectrode arrays. Serendipitously, we found that our microtunnels had an extraordinary effect on signal-to-noise ratio and the quality of electrophysiological recordings with regards to number of active channels and detected spikes. Since we often found the neuronal growth surprising, we developed a simple computer model which could reproduce neuronal growth in the various tunnels, allowing computer aided design (CAD) of future projects.