Application Summary
Researchers at NYU Abu Dhabi developed a novel helical-shaped intracerebral microfluidic catheter—called SPIRAL (Strategic Precision Infusion for Regional Administration of Liquid)—to improve localized drug delivery in the brain. Traditional straight catheters often require multiple insertions to reach wider or irregular regions of the brain, increasing the risk of tissue trauma and inflammation. The team sought a new design that could distribute drugs across larger tissue volumes while maintaining a minimal footprint and mechanical compatibility with soft brain tissue.
Bringing the SPIRAL Concept to Life Through Micro-Scale Fabrication
To turn their computational model into a working implant, the researchers relied on Boston Micro Fabrication’s microArch S240 3D printer. Using Projection Micro Stereolithography (PµSL) with 10 µm XY resolution and 20 µm layer thickness, the team successfully fabricated:
- Helical microcatheters with 0.3 mm wall thickness and multiple 88.45µm outlet ports
- Surgical prototypes and matching insertion apparatuses with 2.5 mm pitch threading for precise, minimally invasive implantation
- Scaled functional models used for fluid flow validation and brain-phantom studies
The fine feature control and dimensional accuracy of BMF’s system were critical for reproducing the fluid-dynamic parameters established in simulation. Other printing methods lacked the precision needed to ensure uniform flow across multiple outlets, a requirement central to the SPIRAL’s performance.
Results and Impact
With these printed prototypes, the team demonstrated that helical catheters can deliver therapeutic agents more evenly and efficiently than straight designs—reaching broader and more complex brain regions through a single implantation. Mechanical tests confirmed greater flexibility and buckling resistance, reducing the chance of fracture during surgical insertion. In vivo experiments in rats showed no increase in gliosis or inflammation, validating the design’s safety.
The success of SPIRAL highlights how high-resolution additive manufacturing can bridge computational design and functional biomedical devices, enabling new strategies for personalized drug delivery in neurological disorders.
