Here, we present a protocol for the design, assembly, and operation of a bubble-free, closed-loop microfluidic device for endothelial cell culture under physiological flow conditions in simulated microgravity.
Method Article
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September 11th, 2026
Here, we present a protocol for the design, assembly, and operation of a bubble-free, closed-loop microfluidic device for endothelial cell culture under physiological flow conditions in simulated microgravity.
Microphysiological systems (MPS) are valuable in vitro models that recreate the structure and function of human tissues. Specifically, tissue- or organ-on-chips that incorporate microfluidic technology replicate the in vivo mechanical and biochemical environment while enabling real-time monitoring of cellular growth and development. These systems can be particularly useful for spaceflight studies, as they can be sent into space, such as to the International Space Station (ISS), to investigate the impact of space travel on the human body. A major impediment to the success of the MPS is the formation of bubbles, which can be pronounced in microgravity. This paper describes the design, assembly, and operation of a microphysiological cell culture system for use in simulated microgravity (e.g., run on a random positioning machine or clinostat). The incorporation of an orientation-independent bubble trap into the fluidic circuit has been shown to be highly effective for removing air bubbles in microgravity and enabling long-term endothelial cell culture. This closed-loop, orientation-independent microfluidic system can be used for bubble-free operation of tissue chips or organ-on-chips to simulate the combined effects of microgravity and flow or for deployment in space missions.
It is now well established, through mechanisms under investigation, that mechanical forces play a critical role in cellular function and in maintaining the fine balance between health and disease1. Of all the environmental stresses, gravitational force is unique and is rightfully assumed to be a constant, intransigent vector in the vast majority of biomedical science. However, spaceflight presents a unique microgravity environment, in which organisms' behavior may differ from that on Earth. Spaceflight experiments involving animals and human subjects show significant changes in physiology, underscoring the role of gravity in cellular and organismal homeostasis2.
Recently, NASA and other private agencies have shown considerable interest in developing tissue chips (or organ-on-chips) for deployment on space missions3. The tissue chips are designed to mimic the in vivo architecture, enabling them to model, with high fidelity, the physiological and mechanistic impact of microgravity and space radiation4. By utilizing donor-derived cells, tissue chips can also be used to investigate the astronaut’s sensitivity to microgravity and space radiation and develop preventive countermeasures5. Over the past five years, several organ systems, including the brain, liver, gut, blood vessels, heart, kidney, and lungs, have been modeled using tissue chips and launched aboard the ISS6. In vivo, organs are perfused by the vasculature to varying degrees, which determines their physiology - for instance, the liver is highly vascularized, whereas cartilage is much less so. Therefore, to accurately recapitulate organ function in vitro, an important consideration in the development of organ-on-chip systems is the incorporation of fluid flow into tissues and cells.
Microfluidics has been used to perfuse cells and tissues in organ-on-chip systems7,8. Appropriate fluid flow levels not only support nutrient transport into and waste product removal from the system but also maintain the physiological shear stress experienced by cells. However, at small dimensions, bubbles pose a persistent challenge at phase boundaries, leading to inaccurate measurements, damage, and blockages9. To mitigate this problem, bubble traps with active (e.g., vacuum degassing or external fields such as acoustic or thermal) and passive (e.g., a semipermeable membrane that depends on surface properties) designs have been used10,11. However, these microfluidic debubbler designs increase device fabrication complexity, compromise sample integrity, and lead to clogging and breaches of the barrier. The problems are exacerbated in space, where nucleation and bubble formation are much more pronounced, and the bubble mitigation strategies that are effective on Earth become largely ineffective12. Ground-based microgravity analogs can be generated using devices such as a rotating wall vessel (RWV) or a random positioning machine (RPM)13,14. Of interest, in RPM, the gravity vector is continuously reoriented, thus nearly zeroing out the time-averaged net gravitational stimulus on the sample. We have recently reported on the design, fabrication, and application of an orientation-independent bubble trap for perfusion culture of endothelial cells under simulated microgravity using an RPM15. In this article, we describe the step-by-step assembly and operation of a closed-loop perfusion system using the orientation-independent bubble trap and demonstrate its applicability for the culture of human umbilical vein endothelial cells as a model for continuous cell culture in simulated microgravity.
The closed-loop system consists of a microcontroller with a motor driver for frequency- and voltage-controlled micropump operation, a liquid flow sensor, a bubble trap15, and a microfluidic channel containing adherent endothelial cells. Specific components are detailed in the Table of Materials. The protocols below describe the assembly of system electronics (Step 1), assembly of fluidics (Step 2), sterilization and priming (Step 3 and 4), microfluidic cell culture integration (Step 4), assembly of micropumps and controller (Step 5), and the assembly of the entire system in an enclosure (Step 6). The closed-loop flow system was mounted atop the RPM to simulate microgravity using a custom-made enclosure (Step 7).
1. System electronics
2. System fluidics connections
3. Experimental Preparation and System Sterilization
4. System priming and microfluidic cell channel integration
5. Microcontroller and micropumps enclosure (Optional)
6. Upper deck mounting plate (Optional)
7. Mounting on the random positioning machine (RPM)
8. Flow data collection
Before collecting results on fluidics or cell culture, as described below, the system integrity should be verified at each major protocol checkpoint throughout the assembly and priming processes. Electronic connections can be easily checked by connecting the microcontroller and liquid flow sensor to a computer and communicating with each component via its respective application software. Tubing connections at barbed fittings are deemed sufficient once the tubing is pushed past the barb, and any fluidic component that has any number of cracks should immediately be replaced. System priming should result in a flow loop that is not only sterile but also visibly bubble-free; dislodge any visible bubbles by gently tapping the bubble location.
After the experimental setup is complete, the flow system should run and be monitored for 1 h prior to the 24 h testing period to ensure there are no leaks in the system and that no air bubbles are observed exiting the bubble trap. In addition, if the flow system is operating under simulated microgravity, the simulated microgravity apparatus must be able to rotate freely after the flow system is mounted, which can be tested by simply rotating the apparatus by hand and also by observing the apparatus running its simulated microgravity program for 1 h prior to the 24 h testing period.
Performance of the closed-loop perfusion system
The output from the flow sensors logged over a 24 h period is presented in Figure 4. The figure compares the flow rate at normal gravity over a 24 h period in a flow loop with and without an orientation-independent bubble trap. The air bubbles are represented by high-intensity spikes. The unrelenting spikes seen in the flow loop without the bubble trap disappear upon the introduction of the orientation-independent bubble trap into the flow loop. This comparison not only demonstrates the necessity of a bubble trap but also the robust performance of the orientation-independent bubble trap.
Endothelial cell culture under flow conditions
To fully evaluate the viability of the bubble-free flow system, a 24 h microgravity experiment was performed with endothelial cell cultures with and without a bubble trap. At the end of the experiment, the system was disassembled, and care was taken to prevent the cells from drying out. Immediately, the cells were fixed with 4% formaldehyde and stained with CF594 phalloidin for actin and Hoechst 33342 for nuclei, following standard immunostaining protocols15. The cells were visualized using confocal microscopy (Zeiss LSM 700). Figure 5 shows representative cell images for each flow condition. The images show that bubble traps (Figure 5B) completely rescue cell viability and growth, whereas cells detach in the channel without a bubble trap (Figure 5A). The nuclei in the images can be quantified for orientation using ImageJ for the case with the bubble trap, since no cells were present in its absence15.

Figure 1. Closed-loop flow system components. Fluid exiting a micropump first enters the bubble trap for bubble filtration, then passes through a sensor for flow data logging before passing into the microfluidic chip. The system is designed to support two flow loops running simultaneously, with only one complete loop shown here. Please click here to view a larger version of this figure.

Figure 2. Flow system subassemblies for mounting on random positioning machine (RPM). The micropumps and electronics are protected inside an enclosure. After priming (i.e., filling with liquid) the upper deck is mounted with threaded rods onto the enclosure, with the microfluidic chip centered in between. Flow sensors and bubble traps are mounted onto the upper deck. The electronics enclosure is fastened to a mounting plate with a crossbar for securing onto the RPM. Two independent flow loops are shown. Please click here to view a larger version of this figure.

Figure 3. Assembled perfusion system mounted on random positioning machine (RPM). The overall perfusion system is secured by screwing the mounting plate crossbar onto the RPM. Electronics power cables are organized by wrapping around the central periphery, ensuring the entire assembly fits within the usable space constraints of the RPM payload deck. Please click here to view a larger version of this figure.

Figure 4. Comparison of representative flow rate plots. Flow rate plot comparison between (A) a flow loop without the orientation-independent bubble trap and (B) a flow loop with the orientation-independent bubble trap. This experiment was performed in normal gravity conditions (i.e., no RPM) with the flow sensor placed immediately before the microslide in both flow loops. Please click here to view a larger version of this figure.

Figure 5. Representative images of endothelial cells cultured under flow conditions with and without an orientation-independent bubble trap. (A) Flow without bubble trap showing low cell adherence; (B) Flow with bubble trap showing high cell adherence. Actin is shown in red and nuclei in blue. Scale bar = 200 µm. Please click here to view a larger version of this figure.
A closed-loop, orientation-independent microfluidic system capable of operating in the absence of gravity has been developed and shown to be viable for the culture of endothelial cells under physiological flow conditions. The key components of the system are a microcontroller, a micropump, a liquid flow sensor, a cell culture microslide, and a custom 3D-printed orientation-independent bubble trap.
The bubble traps used in this work are fabricated from stereolithography resin15, which generally has low cytocompatibility when used without pre-leaching of non-polymerized monomers, even for biomedical-grade resins17,18. Thus, before implementing the bubble trap in the system, it is important to assess whether chemical leachate from the custom-fabricated bubble trap material may compromise cell viability.
Cytocompatible material choices aside, the most crucial steps in the experimental setup protocols are bubble-trap sealing, microslide submersion for priming, and cable organization when using a simulated microgravity apparatus. After the primed fluid system is observed to be bubble-free, the bubble trap’s top port must be hermetically sealed with Teflon tape and a Luer plug to prevent leakage. Inherent surface roughness in the layers of stereolithography printing for custom fabrication means the Luer plug alone is not adequate for good sealing. Submersion of the microslide in a reservoir of cell culture medium was found to be the most effective method for ensuring a bubble-free priming job, specifically at the elbow connector-to-microslide junction. Other priming methods tried, such as incorporating 3-way stopcocks into the flow loop, tended to leave a significant number of bubbles post-priming that were nearly impossible to dislodge without removing the elbow connector from the microslide. Finally, disorganized electronic cables can obstruct the simulated microgravity apparatus, causing it to inadvertently halt. Even after fastening all cables and verifying that the apparatus can freely rotate prior to experimentation, the system and apparatus should still be monitored every 3–4 waking hours to minimize the risk of halting.
This system may be adapted for more complex cell culture or three-dimensional (3D) tissue chips and has the potential to be a valuable tool for advancing in vitro models to understand disease mechanisms, support drug development, assess the effects of spaceflight stressors, and prepare countermeasures. For example, the engineered tissue platforms launched to the ISS have been used to understand the effects of microgravity and radiation exposure5, and the extreme environment of microgravity has been used to mimic aging phenotypes or to generate large multicellular spheroids to study cancer19. In all such cases, the orientation-independent bubble trap and the flow system can be used to either understand the effect of shear stress or tailor mass transport for desired outcomes.
Relative to other approaches for cell culture, the system presented here has two key advantages: (1) providing continuous, closed-loop flow and (2) being compact and self-contained. Some cell-culture approaches rely on static flasks or wells, which lack the physiologically mimicking fluid shear stress. Some commercial systems (e.g., ibidi Pump System, Gräfelfing, Germany) can achieve continuous, unidirectional flow by cross-over switching valves between alternating syringes. However, operation of such an apparatus typically requires a separate computer-interfaced actuator control system, rendering it neither compact nor self-contained. In addition, integrating the robust bubble trap described in this paper facilitates unattended, long-duration experiments.
One potential modification to the system in future iterations is the micropump, specifically to explore the effects of higher shear stress on endothelial cells. The micropumps used in the representative data were only capable of producing shear stresses up to 7.5 dyn/cm2, whereas endothelial cells in vivo are typically exposed to shear stresses nearly threefold higher20. Potential future applications of this system beyond continuous cell culture in simulated microgravity include other portable applications that require continuous liquid recirculation. Such possibilities include drug screening, fouling or toxicity assays, corrosion testing, liquid-cooling of electronics, and environmental monitoring of pollutants.
The omnidirectional bubble trap is protected by the patent application US 18634723. There are no additional competing interests.
This work was supported by the NASA Space Biology grant # 80NSSC21K0272.
| Name | Company | Catalog Number | Comments |
|---|---|---|---|
| 100% ethanol | Fisher Scientific | A4094 | Used to create a 70% ethanol solution for system sterilization (Minimum need 35 mL) |
| 6 mm black nylon round spacer, 7 mm OD, 3.2 mm ID | Exqutoo | ZH-0050 | Secures top mount to enclosure (Minimum need 4) |
| Acrylic plate, 75 mm long x 25 mm wide | Polymersan | ACRCS | Secures elbow Luer adapters to the microchannel slide (Minimum need 1) |
| A-male to mini-B cord USB 2.0 Cable | Ugreen Group Limited | 10355 | For connecting the computer to the microcontroller (Minimum need 1) |
| Bubble trap | (Custom) | For preventing bubble passage to the microslide (Minimum need 1) | |
| Bubble trap holder | Custom | 3D printed holder to keep bubble trap in place (Minimum need 2) | |
| Cell culture grade water | Fisher Scientific | MT25055CI | Used to flush out all traces of ethanol post-sterilization (Minimum need 30 mL) |
| Controller, pump, and enclosure mount (interior mount) | Custom | Mounting plate inside enclosure (Minimum need 1) | |
| Cross bar mount | Custom | Mounting cross bar attached enclosure mounting plate (Minimum need 1) | |
| DB15 breakout male + female connectors | ANMBEST | ANMBEST_MDDB15 | For connecting the computer to the random positioning machine and then to the microcontroller (Minimum need 1) |
| Elbow Luer to barb connector | ibidi | 10802 | Connects microslide to the flow loop (Minimum need 2) |
| Double-sided foam tape | 3M | 4026 | For compression of elbow Luer adapters on microchannel slide (Minimum need 1) |
| Enclosure (60 mm x 140 mm x 140 mm) | Hammond | 1554Q2GYCL | Houses the microcontroller and the micropumps (Minimum need 1) |
| Enclosure mount (bottom mount) | Custom | Mounting plate beneath enclosure (Minimum need 1) | |
| Female-female Luer coupler | Boao | Boao-Syringes-WAD2354 | Used to connect syringe to elbow Luer connector for cell culture medium priming (Minimum need 1) |
| Gibco RPMI 1640 cell culture medium | Thermo Fisher | 11875093 | Used to culture the endothelial cells (Minimum need 50 mL) |
| Grommets, 9/16" hole diameter and 1/8" thickness, 1/8" ID | McMaster-Carr | 9307K863 | For running tubing in and out of enclosure (Minimum need 8) |
| IDEX P-646 adapter fitting, 1/16" barb to 1/4-28 | IDEX | P-646 | Connects flow sensor to the flow loop (Minimum need 2) |
| Liquid flow sensor | Sensirion | SLF3-1300F | For flow data collection (Minimum need 1) |
| Liquid flow sensor mounting clamp | Sensirion | SLF3x Mounting Clamp | SLF3x mount (Minimum need 2) |
| Luer lock syringe (12 mL) | McKesson | 414624 | For vacuum priming (Minimum need 1) |
| Luer plug | Cole-Parmer | UX-50110-33 | For sealing the orientation-independent bubble traps (Minimum need 1) |
| M2 stainless steel nut | VIGRUE | B07PJQC7T6 | Secures liquid flow sensors to top mount (Minimum need 4) |
| M2×8 stainless steel screw | VIGRUE | B07PJQC7T6 | Secures liquid flow sensors to top mount (Minimum need 4) |
| M3 male-female nylon hex spacer standoff | Meijubol | B0GC6GN9S7 | Secures mp-Multiboard to interior mount (Minimum need 4) |
| M3 nylon washer | Sutemribor | 7.81573E+11 | Secures enlosure to bottom mount (Minimum need 16) |
| M3 stainless steel nut | VIGRUE | B07PJQC7T6 | Secures enclosure to bottom mount, cross bar to bottom mount, pump holder to interior mount (Minimum need 16) |
| M3 stainless steel washer | VIGRUE | B07PJQC7T6 | Secures cross bar to bottom mount, enclosure to bottom and inner mount, interior mount to pump holder (Minimum need 12) |
| M3×12 stainless steel button head screw | VIGRUE | B07PJQC7T6 | Secures enclosure to bottom mount (Minimum need 4) |
| M3×12 stainless steel socket cap screw | Fgruh | FG001-3 | Secures bubble trap holder to upper deck mount (Minimum need 2) |
| M3×6 Phillips pan head screw | Meijubol | B0GC6GN9S7 | Secures mp-Multiboard to interior mount (Minimum need 4) |
| M3×8 stainless steel screw | VIGRUE | B07PJQC7T6 | Secures cross bar to bottom mount, enclosure to interior mount, pump holder to interior mount (Minimum need 8) |
| M4 stainless steel nut | VIGRUE | B07PJQC7T6 | Secures top mount to enclosure (Minimum need 4) |
| M4 stainless steel washer | VIGRUE | B07PJQC7T6 | Secures top mount to enclosure (Minimum need 4) |
| M4-0.7 steel threaded rod | Arwnnklo | AR01 | Cut to ~6 inch lengths (Minimum need 4) |
| Male to female mini USB cable | Plinkwirekb | PCM-0725-L | For connecting the computer to the microcontroller (Minimum need 1) |
| Male to female mini USB right angle connector | UCEC | 4326453558 | For connecting the computer to the microcontroller (optional) (Minimum need 1) |
| Microchannel holder | Custom | 3D printed holder to keep microchannel centered (Minimum need 1) | |
| Microchannel slide, µ-slide VI 0.4 | ibidi | 80606 | For cell assays under flow (Minimum need 1) |
| Micropump | Bartels | MP6-HYB | For producing flow (Minimum need 1) |
| Micropump holder | Custom | Mounting fixture to hold micropump (Minimum need 1) | |
| mp-Multiboard with mp-Highdriver4 | Bartels | BM-E-0005 | For controlling the frequency and voltage settings of the micropumps (Minimum need 1) |
| mp-pump Cable | Bartels | BM-A-0055 | Used to electrically connect mp-Multiboard to the micropumps (Minimum need 1) |
| Nylon round spacer, 7 mm OD, 3.2 mm ID | Harfington | 2037015 | For securing tubing to micropump (Minimum need 2) |
| O-ring | ZDBB | 7.17327E+11 | Secures the male to female mini USB cable to the enclosure (optional) (Minimum need 3) |
| Plastic container | Herdusa | HDS10 PLASTIC BOX | Used as open reservoir for cell culture medium (Minimum need 1) |
| Polyurethane tubing, 1/8" I.D., 1/4" O.D. | PARKER | 95U-4-062-BLU-0100 | Secures top mount to enclosure (Minimum need 1.6 cm) |
| Random positioning machine | AIRBUS | Random Positioning Machine 2.0 (Minimum need 1) | |
| SCC1-USB cable | Sensirion | SCC1-USB 2M | Connects liquid flow sensors to computer (Minimum need 1) |
| Self-standing centrifuge tube | PEKYBIO | B0C13GZVD6 | Used to hold cell culture water/70% ethanol (Minimum need 2) |
| Spacer, 8 mm OD, 20 mm long aluminum | McMaster-Carr | 94669A062 | Minimum need 4 |
| Tygon PVC 1/16" ID x 1/8" OD | Saint-Gobain | B-44-3 | Connects all flow loop components (Minimum need 40 cm) |
| Upper deck mount | Custom | Mounting plate connected to liquid flow sensors and bubble trap (Minimum need 1) | |
| Wing nut, M4 x 0.7 mm, zinc-plated steel | Siptenk | S-TH-DLM-002 | Secures top mount to enclosure (Minimum need 4) |
| Zip-tie | HAVE ME TD | 7.32073E+11 | Secures cables when mounting system to RPM (Minimum need 4) |
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