A biodegradable porous membrane-based lung alveoli-on-a-chip for assessing particulate-matter-induced pulmonary toxicity

Understanding how airborne particulates disrupt the human alveolar barrier requires in vitro systems that accurately replicate its composition and function. We present a biodegradable lung alveoli-on-a-chip that reproduces the architecture and physiology of the human air-blood interface using a porous poly(lactic-co-glycolic acid) (PLGA) membrane positioned between epithelium and endothelium under air-liquid interface (ALI) culture. The membrane, fabricated by porogen-assisted nonsolvent-induced phase separation, exhibited >50 % porosity, [~]2 {micro}m thickness, and mechanical compliance over 100-fold higher than conventional Transwell inserts, closely resembling the native interstitium. During co-culture, gradual PLGA degradation was compensated by cell-secreted extracellular-matrix (ECM) proteins such as collagen IV and laminin, forming a self-remodeling barrier that maintained integrity for at least 11 days. The platform supported stable epithelial-endothelial co-culture, high transepithelial electrical resistance, and physiologically relevant permeability. To demonstrate its utility, the chip was used to assess pulmonary toxicity of four types of waste-combustion-derived particulates, including rubber, plastic bags, plastic bottles, and textile fibers, delivered apically under ALI conditions. All combustion products reduced cell viability, increased hydrogen-peroxide release, and elevated {gamma}-H2AX expression, indicating oxidative and genotoxic stress, while disrupting barrier permeability. Rubber combustion particles elicited the most severe toxicity, causing the greatest loss of viability, accumulation of reactive oxygen species, and formation of DNA double-strand breaks. Together, these results establish a biodegradable, ECM-remodeling lung alveoli-on-a-chip as a physiologically relevant platform for investigating source-specific particulate toxicity and alveolar-barrier pathophysiology. By bridging environmental exposure models with human-relevant lung biology, this system provides a quantitative and translatable tool for evaluating respiratory risks and therapeutic interventions.