Microneedle patch casting using a micromachined carbon master for enhanced drug delivery

Area of Science:

• Biomaterials Engineering
• Drug Delivery Systems
• Nanotechnology

Background:

• Microneedle applications for therapeutic delivery and analytics are limited by small surface areas for drug loading and sampling.
• Painless administration and improved drug penetration are key challenges in microneedle technology.

Purpose of the Study:

• To design and fabricate patch-type microneedle arrays (MNAs) for enhanced drug loading, analytics sampling, and improved drug penetration.
• To develop a microneedle patch with controlled drug release capabilities using a pH-sensitive polymer.
• To demonstrate the potential of these MNAs for improved disease treatment protocols.

Main Methods:

• Fabrication of MNAs using polymer casting from a conical cavity mold with microcavities formed on a carbon plate.
• Coating the microneedle patch (MNP) with a porous polymer layer for drug loading and channels.
• Application of a pH-sensitive polymer layer to cap the porous layer, controlling leakage and enabling stimulus-responsive release.

Main Results:

• The developed MNPs demonstrated sufficient space and channels for drug loading and analytics sampling.
• In vitro and in vivo studies confirmed the drug release capabilities of the microneedle patches.
• The pH-sensitive capping layer effectively prevented leakage and enabled controlled drug release.

Conclusions:

• The fabricated microneedle patches show significant potential for enhancing therapeutic delivery and disease treatment.
• The design allows for flexibility in coating and therapeutic materials, offering scope for further advancements.
• These microneedle arrays represent a promising platform for painless, efficient drug delivery and analytics sampling.