Rapid assembly of PMMA microfluidic devices with PETE membranes for studying the endothelium

Biomicrofluidic devices and organ-on-a-chip (OOC) systems with integrated membranes are often fabricated from two different thermoplastic materials but bonding of such dissimilar thermoplastics remains challenging to manufacture at scale. Here, we present a method to bond poly(methylmethacrylate) layers to a polyethylene terephthalate porous membrane to create membrane-based microfluidic devices for biological barrier modeling. By combining milling, laser cutting and chlorocarbon-based solvent bonding supported by retention grooves, we achieved a fabrication rate of 36 devices in 5 h. Chlorocarbon-based solvent bonding resulted in bond strength of ~10 J/m2 and did not adversely affect the membrane pore structure or the channel cross-sectional shape. The bonded devices were found to support long term culture of human endothelial cells that developed expected morphology and cell-cell adhesion contacts as evidenced by immunofluorescent labeling of VE-cadherin. Barrier permeability was measured to be 3.38 × 106 cm/s for 10 kDa dextran using a sampling-based method compatible with mass spectrometry and scintillation techniques and was in agreement with literature. To validate the devices for cell migration experiments, THP-1 monocytes were introduced into devices with confluent endothelial monolayers. Monocytes adhered to and migrated through the endothelium. Activation of the endothelium with TNF-α prior to introducing monocytes significantly increased monocyte adhesion. Overall, the rapid device fabrication method achieved medium-volume production rates and was found to support both cell culture and experiments associated with measuring barrier and endothelial function. This fabrication method has potential to both accelerate biomicrofluidics and OOC research in the lab and accelerate development of commercialized microfluidic membrane devices.