Vascular tree structure-based perfusion phantom fabrication using modified Hele-Shaw Cell technique

Tissue phantoms that mimic microvasculature and perfusion are essential for modelling vascular function, guiding interventions, and calibrating imaging systems, which require faithful replication of vascular geometry and flow. Conventional fabrication strategies, including wire-based molding, lithographic micromachining, and additive manufacturing, offer useful capabilities but remain constrained by predefined designs, rectangular channel cross-sections, limited scalability, and high production costs. Reliance on predefined digital vascular models restricts design flexibility and limits the ability to capture the natural variability and complexity of real vascular systems. Here, we present a lithography-free, fractal-generating approach based on a modified Lifted Hele-Shaw Cell (LHSC) technique, in which vascular networks emerge spontaneously via interfacial fluid instabilities. Unlike pre-designed methods, these structures are governed by fluid properties and flow conditions, enabling adaptive, physiologically relevant geometries with smooth Gaussian cross-sections and natural diameter tapering. We demonstrate four phantom designs: a planar vascular tree, an anatomically guided cerebral network, a retinal vascular model, and a conformable curved substrate phantom. Validation using Laser Speckle Contrast Imaging confirms structural fidelity and physiologically relevant flow consistent with Murrays law. This platform uniquely integrates realistic vascular architecture with emergent, fractal driven formation, highlighting its potential as a reproducible and biologically relevant alternative to conventional vascular phantom fabrication. Furthermore, the availability of such realistic in vitro vascular models can reduce reliance on animal experiments and contribute towards more ethical and sustainable preclinical research.