Implementing meso-scale surface patterns on polymeric substrates for blood-contact applications

Mesoscopic topological cues offer a promising strategy for promoting stable endothelial cell layers and reducing thrombogenicity in medical devices. In this study, a hybrid method including lithography and electrodeposition was developed to fabricate large, permeable, fiber-based scaffolds with mesoscale patterns mimicking the basement membrane. Three different patterns were created using laser lithography on substrates with varying photoresist thicknesses (1 μm and 4 μm) and transferred via electrodeposition onto electrospun fiber networks. The technique achieved high pattern transfer accuracy. Fiber alignment, quantified by an orientation index, demonstrated a significant correlation between pattern thickness and fiber organization in square and groove geometries at 4 μm, where anisotropic alignment was observed. In contrast, 1 μm patterns showed more random fiber orientation, attributed to insufficient depth for effective fiber attraction. This scalable and biocompatible approach highlights the potential of hybrid fabrication methods for creating advanced scaffolds suitable for biomedical applications.