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Micromechanical Punching: A Versatile Method for Non-Spherical Microparticle Fabrication.

Ritika Singh Petersen1,2, Anja Boisen1,3, Stephan Sylvest Keller1,2

  • 1DNRF and Villum Fonden Center for Intelligent Drug Delivery and Sensing Using Microcontainers and Nanomechanics, IDUN, DTU Health Technology, Technical University of Denmark, 2800 Kgs. Lyngby, Denmark.

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|December 31, 2020
PubMed
Summary

A new Micromechanical Punching (MMP) method fabricates non-spherical microparticles from solid sheets, expanding material options beyond liquid-based techniques for applications in drug delivery and beyond.

Keywords:
drug deliverynon-spherical microparticlepunchingsoft lithography

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Area of Science:

  • Materials Science
  • Nanotechnology
  • Chemical Engineering

Background:

  • Microparticles are crucial in diverse fields like electronics, drug delivery, cosmetics, and food.
  • Conventional methods like particle replication in non-wetting template (PRINT) process materials in liquid states, limiting fabrication options.
  • Existing techniques restrict the choice of materials for both microparticles and molds.

Purpose of the Study:

  • To introduce a novel, high-throughput microfabrication technique for non-spherical microparticles.
  • To overcome the material limitations of existing liquid-based microparticle fabrication methods.
  • To demonstrate the versatility and accessibility of the new technique for various applications.

Main Methods:

  • Micromechanical Punching (MMP), inspired by macro-manufacturing, uses a robust mold to punch microparticle material from a sheet placed on a deformable substrate.
  • This cleanroom-free technique processes prepatterned, porous, and fibrous films made of thermoplastics and thermosetting polymers.
  • The method allows for the fabrication of microparticles from solid-state materials.

Main Results:

  • MMP enables the high-throughput production of non-spherical microparticles from a wider range of solid materials.
  • Fabrication of Furosemide-embedded poly(lactic-co-glycolic acid) microdisks was demonstrated, showing potential for drug delivery applications.
  • The study successfully produced microparticles from various polymer films.

Conclusions:

  • Micromechanical Punching (MMP) offers a versatile and accessible approach for micro/nanofabrication of engineered particles.
  • The technique expands the material scope for microparticle production compared to traditional liquid-based methods.
  • MMP has significant potential for research and industrial communities requiring custom microparticle fabrication.