A newly developed 3D lung model from University of Delaware researchers enables unprecedented evaluation of inhaled therapeutics and environmental exposures, addressing key challenges in respiratory medicine and toxicology.
Innovative approach to a persistent challenge
Respiratory diseases remain notoriously difficult to treat effectively, with inhalable medications showing promise but facing significant hurdles in optimising delivery to specific lung regions. The complex architecture of human lungs – branching from centimetre-sized airways to microscopic alveoli roughly 100 microns wide – creates a labyrinthine pathway for aerosol medications that has proven difficult to model accurately.
University of Delaware Centennial Associate Professor Catherine Fromen and her research team have developed an adaptable 3D lung model that represents a significant advance in respiratory research capabilities. Their work, published in the journal Device in February 2025, demonstrates a system that can replicate realistic breathing patterns whilst offering personalised evaluation of aerosol therapeutics under various conditions.
Unique dual-functionality design
What distinguishes this new model from existing technologies is its combination of two critical features: cyclic breathing motion that mimics natural lung function, and innovative lattice structures created through 3D printing that represent the entire volume and surface area of human lungs.
“There’s nothing currently out there that has both of these features,” explained Fromen, who holds joint appointments in chemical, biomolecular and biomedical engineering. “This means that we can look at the entire dosage of an inhaled medicine. We can look at exposure over time, and we can capture what happens when you inhale the medication and where the medicine deposits, as well as what gets exhaled as you breathe.”
Rigorous testing methodology
The model enables researchers to track aerosol deposition throughout the respiratory system by incorporating fluorescent molecules into test solutions. After exposure, each of the model’s 150 components is analysed to determine precisely where and in what concentration the aerosols have deposited.
“We wash each part and rinse away everything that deposits. The fluorescence is just a molecule in the solution. When it deposits, we know the concentration of that, so, when we rinse it out, we can measure how much fluorescence was recovered,” Fromen said.
This detailed data allows the creation of comprehensive heat maps showing aerosol deposition patterns, which can be validated against clinical benchmarks.
Applications beyond pharmaceutical development
While the model currently replicates healthy lung function under normal breathing conditions, Fromen’s team is working to expand its capabilities to simulate various respiratory diseases and conditions.
“An asthma attack, exercise, cystic fibrosis, chronic obstructive pulmonary disorder (COPD) – all those things are going to really affect where aerosols deposit. We want to make sure our model can capture those differences,” Fromen noted.
Beyond pharmaceutical applications, the technology is already finding utility in environmental toxicology. A newly funded project with the Army Research Lab aims to understand environmental exposures – tracking particle penetration depth, quantities, and regional deposition patterns in the lungs.
The Delaware researchers have shared their design and methods in an open-source format to encourage adoption by other scientists, potentially fostering collaborations with clinicians providing patient profiles and pharmaceutical developers optimising treatment approaches.
The research team has submitted a patent application through the University of Delaware’s Office of Economic Innovation and Partnerships.
Reference:
Fromen, C. A., et al. (2024). Adaptable 3D lung model for personalized evaluation of aerosol therapeutics under various breathing conditions. Device. https://doi.org/10.1016/j.device.2024.100514
