3D-printed lung model helps researchers study aerosol deposition in the lungs

Feb 24, 2025

4 min


Treating respiratory diseases is challenging. Inhalable medicines depend on delivering particles to the right lung areas, which is complicated by factors like the drug, delivery method and patient variability, or even exposure to smoke or asbestos particles. University of Delaware researchers have developed an adaptable 3D lung model to address this issue by replicating realistic breathing maneuvers and offering personalized evaluation of aerosol therapeutics.


“If it's something environmental and toxic that we're worried about, knowing how far and how deep in the lung it goes is important,” said Catherine Fromen, University of Delaware Centennial Associate Professor for Excellence in Research and Education in the Department of Chemical and Biomolecular Engineering. “If it's designing a better pharmaceutical drug for asthma or a respiratory disease, knowing exactly where the inhaled aerosol lands and how deep the medicine can penetrate will predict how well that works.”that can replicate realistic breathing maneuvers and offer personalized evaluation of aerosol therapeutics under various breathing conditions.


Fromen and two UD alumni have submitted a patent application on the 3D lung model invention through UD’s Office of Economic Innovation and Partnerships (OEIP), the unit responsible for managing intellectual property at UD.


In a paper published in the journal Device, Fromen and her team demonstrate how their new 3D lung model can advance understanding of how inhalable medications behave in the upper airways and deeper areas of the lung. This can provide a broader picture on how to predict the effectiveness of inhalable medications in models and computer simulations for different people or age groups. The researchers detail in the paper how they built the 3D structure and what they’ve learned so far.


Valuable research tool

The purpose of the lung is gas exchange. In practice, the lung is often approximated as the size of a tennis court that is exchanging oxygen and carbon dioxide with the bloodstream in our bodies. This is a huge surface area, and that function is critical — if your lungs go down, you're in trouble.


Fromen described this branching lung architecture like a tree that starts with a trunk and branches out into smaller and smaller limbs, ranging in size from a few centimeters in the trachea to about 100 microns (roughly the combined width of two hairs on your head) in the lung’s farthest regions. These branches create a complex network that filters aerosols as they travel through the lung. Just as tree branches end in leaves, the lung’s branches culminate in delicate, leaf-like structures called alveoli, where gases are exchanged.


“Those alveoli in the deeper airways make the surface area that provides this necessary gas exchange, so you don't want environmental things getting in there where they can damage these sensitive, finer structures,” said Fromen, who has a joint appointment in biomedical engineering.


Mimicking the complex structure and function of the lung in a lab setting is inherently challenging. The UD-developed 3D lung model is unique in several ways. First, the model breathes in the same cyclic motion as an actual lung. That’s key, Fromen said. The model also contains lattice structures to represent the entire volume and surface area of a lung. These lattices, made possible through 3D printing, are a critical innovation, enabling precise design to mimic the lung's filtering processes without needing to recreate its full biological complexity.


“There's nothing currently out there that has both of these features,” she explained. “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.”


The testing process

Testing how far an aerosol or environmental particle travels inside the 3D lung model is a multi-step process. The exposure of the model to the aerosol only takes about five minutes, but the analysis is time-consuming. The researchers add fluorescent molecules to the solution being tested to track where the particles deposit inside the model’s 150 different parts.


“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 data allows them to create a heat map of where the aerosols deposit throughout the lung model’s airways, which then can be validated against benchmarked clinical data for where such aerosols would be expected to go in a human under similar conditions.


The team’s current model matches a healthy person under sitting/breathing conditions for a single aerosol size, but Fromen’s team is working to ensure the model is versatile across a much broader range of 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 said.


The ability to examine disease features like airway narrowing or mucus buildup could lead to more personalized care, such as tailored medication doses or redesigned inhalers. Currently, inhaled medicines follow a one-size-fits-all approach, but the UD-developed model offers a tool to address these issues and understand why many inhaled medicines fail clinical trials.

You might also like...

Check out some other posts from University of Delaware

1 min

Food is medicine, and this professor has the research to prove it

For more than 20 years, Dr. Allison Karpyn has worked to understand and address food insecurity in America and beyond — studying how communities access healthy food, how policy shapes those opportunities and how local partnerships can make meaningful change. A professor in the University of Delaware’s College of Education and Human Development and co-director of its Center for Research in Education and Social Policy, Karpyn has published extensively on topics including food deserts, healthy corner store initiatives, school nutrition programs and strategies to bring farmer’s markets to underserved areas. Her work, which blends rigorous research with community-based implementation, has appeared in leading journals such as Pediatrics, Preventive Medicine and Health Affairs. Karpyn has also worked directly with nonprofit organizations, government agencies and retailers to pilot and evaluate programs designed to increase access to high-quality food in low-income neighborhoods. Her focus is on actionable, data-informed solutions to persistent challenges — from childhood hunger to structural barriers in the food supply system. Now, Karpyn’s expertise is being tapped as part of Delaware’s new Food is Medicine Committee, a statewide initiative under the Delaware Council on Farm and Food Policy. The committee seeks to connect nutrition and health care to improve outcomes, lower costs and strengthen local food systems — goals that align closely with Karpyn’s career-spanning mission. For journalists exploring food policy, hunger, public health and the future of food access, Karpyn is a key source of insight, research and real-world perspective. She can be contacted by clicking her profile. 

2 min

Mental health risks spike for young LGBTQ+ men of color, new study shows

As Pride Month shines a spotlight on the progress and resilience of LGBTQ+ communities, it also serves as a reminder of the ongoing challenges — especially the toll that stigma continues to take on mental health. A new in Developmental Psychology study from the University of Delaware’s Eric Layland, assistant professor in the College of Education and Human Development, reveals just how urgent the need for tailored mental health support is — particularly for Black, Latinx and Afro-Latinx gay, bisexual and other sexual minority young men. Published during a time when national attention turns toward LGBTQ+ visibility, the study tracks the mental health trajectories of over 400 cisgender men between the ages of 18 and 29, focusing on how experiences of racism, heterosexism, or both — what Layland terms compound stigma — influence patterns of depression and anxiety. The results are stark: participants who experienced frequent racism and heterosexism across relationships and settings showed the earliest and most severe symptoms of anxiety and depression, with mental health challenges peaking during late adolescence and early adulthood. While symptoms tended to decline by age 24, these years — critical for education, identity formation and economic independence — were marked by emotional strain. "This study emphasizes how multiple sources of discrimination converge to impact the mental health of sexual minority men of color," Layland said. The research calls for early, culturally responsive mental health interventions that help young sexual minority men of color cope with stigma and build resilience. Layland’s team points to interventions that not only teach coping skills but also foster connection, celebrate cultural identity and create peer networks for support. Layland, who specializes in LGBTQ+ development and affirmative interventions, underscores the importance of systemic change as well.  “We need clinical and community resources that are adapted to address the intersecting discrimination experienced by sexual minority men of color, especially in their late teens in early twenties,” said Layland. Supported by the National Institute on Drug Abuse, the National Institute on Mental Health and UD, this study arrives at a crucial time for researchers, educators and community organizations working to create more inclusive and supportive environments. For journalists covering Pride, mental health, or intersectional equity, Layland’s work offers a powerful, data-driven look at what young LGBTQ+ people of color are facing — and how communities can act to change that story.  Journalists can reach Layland by clicking on his profile. 

2 min

Kyle Davis wins NSF CAREER Award for pioneering research on climate-resilient food systems

University of Delaware assistant professor Kyle Davis has received a National Science Foundation (NSF) CAREER Award—one of the most competitive and prestigious honors for early-career faculty—for his work advancing the climate resilience of global food systems. Davis, who holds joint appointments in the College of Earth, Ocean and Environment and the College of Agriculture and Natural Resources, leads cutting-edge research at the intersection of agriculture, sustainability and global environmental change. His focus? Making food production more efficient, climate-smart and socially equitable—especially in regions grappling with limited water resources. With a growing global population and increasing pressure on land and water, Davis’s research is helping to answer one of the most critical questions of our time: How can we feed the world without destroying the planet? His lab’s work recently led to the development of MIRCA-OS, a groundbreaking open-source dataset that offers high-resolution global data on irrigated and rain-fed croplands across 23 crop types. The tool, co-created with UD doctoral student Endalkachew Kebede and published in Nature Scientific Data, allows researchers, farmers and policymakers to assess how crop choices, rainfall and irrigation interact with water systems and food security. Some of the thirstiest crops are grown in the most water-stressed areas Davis said. Shifting crop mixes to crops that require less water but still ensure farmer profits is a promising way to reduce the amount of water needed to irrigate crops and to avoid conditions of water scarcity. Davis’s research spans continents, with active projects in the United States, India, China and Nigeria, where his team is exploring solutions to water scarcity, crop nutrition and agricultural sustainability. His work has appeared in Earth.com, Phys.org and major scientific journals. In 2023, he was recognized with the American Geophysical Union’s Global Environmental Change Early Career Award. In addition to research, Davis is a dedicated mentor, guiding graduate students from around the world. “So much of my research is the result of their passion, abilities, drive and creativity,” Davis said. Davis is available for interviews on topics including sustainable agriculture, water use, climate adaptation, food systems and the power of data science in global development. He can be contacted by clicking the "View Profile" button.

View all posts