Additive Manufacturing of Patient‐Specific Intracranial Aneurysm Cell Culture Models

ABSTRACT Intracranial aneurysms (IAs) affect 2%–6% of the population, with rupture causing 30%–50% mortality and lifelong disabilities in survivors. Limited understanding of the mechanisms underlying IA rupture hinders the development of effective treatment guidelines. This study investigates additive manufacturing techniques to fabricate patient‐specific IA culture models for in vitro investigation of IA pathophysiology. Material compatibility of several 3D printed resins, polydimethylsiloxane (PDMS), and collagen gel with immortalized human brain endothelial cells (HBECs) was investigated. Three fabrication methods were explored: digital light printing (DLP) of a water‐soluble sacrificial core embedded in PDMS, chocolate injection moulding of a sacrificial core embedded in PDMS, and stereolithography 3D printing. Models were cellularized and analyzed for geometric accuracy and distension. PDMS, collagen gel, and elastic50A resin supported over 95% cell viability with continued proliferation. All three methods produced basilar artery IA models with Dice‐Sørensen coefficients over 90%. However, only PDMS models offered complete cell coverage in 3D geometries. Tunable wall thickness enabled localized distension under pressure, mimicking thin‐ and thick‐walled aneurysms. PDMS molded into IA geometries using DLP or chocolate injection moulding, enables high‐fidelity models suitable for cell culture, supporting future studies into the role of fluid shear and mechanical strain in IA rupture.