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<p>Three-dimensional (3D) printing technology is increasingly being utilized as a rapid prototyping method for manufacturing molds for polydimethylsiloxane (PDMS)-based microdevices. Residual photoinitiators and other leachable components derived from photocurable resins often inhibit PDMS curing, while the surface roughness introduced by layer-by-layer printing is known to degrade device performance in cell culture applications. In this study, we propose a surface modification strategy using dip coating with water-soluble and biocompatible poly(vinyl alcohol) (PVA) to improve the compatibility of 3D-printed molds with PDMS replication. Systematic characterization revealed that PVA concentration governs film viscosity and thickness, with the 3–18% (w/w) range yielding uniform and reproducible coatings. PVA-coated molds effectively suppressed PDMS curing inhibition and reduced surface roughness by up to 80%, enabling high-fidelity replication of microstructures. Furthermore, PDMS microwell arrays fabricated from PVA-coated molds supported efficient and uniform embryoid body (EB) formation from human induced pluripotent stem (iPS) cells, with an increased frequency of single EB per well compared to uncoated molds. These findings demonstrate that PVA coating provides a facile, biocompatible, and shape-preserving post-treatment to overcome key limitations of 3D-printed molds. The proposed method offers a robust and accessible pathway for the rapid prototyping of PDMS-based microdevices for stem cell culture and broader biomedical applications.</p>

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PVA-coated 3D-printed molds for rapid prototyping of PDMS microdevices for stem cell culture

  • 期刊论文

  • 发表日期：

    2026年2月11日

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  • Yuma Abe,
  • Daiki Fukai,
  • Taro Toyoda,
  • Naoto Fukumoto,
  • Kyohei Terao

摘要

Three-dimensional (3D) printing technology is increasingly being utilized as a rapid prototyping method for manufacturing molds for polydimethylsiloxane (PDMS)-based microdevices. Residual photoinitiators and other leachable components derived from photocurable resins often inhibit PDMS curing, while the surface roughness introduced by layer-by-layer printing is known to degrade device performance in cell culture applications. In this study, we propose a surface modification strategy using dip coating with water-soluble and biocompatible poly(vinyl alcohol) (PVA) to improve the compatibility of 3D-printed molds with PDMS replication. Systematic characterization revealed that PVA concentration governs film viscosity and thickness, with the 3–18% (w/w) range yielding uniform and reproducible coatings. PVA-coated molds effectively suppressed PDMS curing inhibition and reduced surface roughness by up to 80%, enabling high-fidelity replication of microstructures. Furthermore, PDMS microwell arrays fabricated from PVA-coated molds supported efficient and uniform embryoid body (EB) formation from human induced pluripotent stem (iPS) cells, with an increased frequency of single EB per well compared to uncoated molds. These findings demonstrate that PVA coating provides a facile, biocompatible, and shape-preserving post-treatment to overcome key limitations of 3D-printed molds. The proposed method offers a robust and accessible pathway for the rapid prototyping of PDMS-based microdevices for stem cell culture and broader biomedical applications.