Silicon dermabrasion tools for skin resurfacing applications

Miniature abrasion tools for potential skin resurfacing applications are created using microelectromechanical systems (MEMS) fabrication technology. The abrading microstructures are formed on silicon wafers by a bulk micromachining process based on isotropic xenon difluoride etching. The micromachined abraders (microdermabraders) are packaged and applied to human cadaveric skin to assess abrasion quality. Plastic (acrylic) microreplicated structures, non-coated and aluminum-coated versions, are also used in a similar fashion. Non-textured silicon and plastic samples are used as study controls. Dermabraded and intact skin regions are analyzed qualitatively and quantitatively by light microscopy, image processing techniques, and histology. The microdermabraders exhibit a cleaner, more uniform abrading pattern on the cadaveric skin compared to the plastic microreplicated structures. Furthermore, the microdermabraders provide a consistently uniform cut through the epidermal layer, leaving little debris and minimal pitting. In contrast, the plastic microreplicated structures exhibit non-uniform abrading patterns and leave behind more debris and eccentric pits. The results suggest micromachined dermabraders can successfully abrade fine dermatological flaws in human skin.