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Solid Microneedles from Poly(3-hydroxybutyrate-co-3-hydroxyvalerate-co-3-hydroxyhexanoate): A Solvent-Free,

Diana Araújo1,2, Francisco Santos1,2,3, Rui Igreja3

  • 1UCIBIO-Applied Molecular Biosciences Unit, Department of Chemistry, School of Science and Technology, NOVA University Lisbon, 2829-516 Caparica, Portugal.

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Summary

This study shows biodegradable poly(3-hydroxybutyrate-co-3-hydroxyvalerate-co-3-hydroxyhexanoate) (PHBHVHHx) microneedles can be fabricated sustainably. These microneedles offer good mechanical strength, insertion ability, and drug delivery potential.

Keywords:
coated MNspoly(3-hydroxybutyrate-co-3-hydroxyvalerate-co-3-hydroxyhexanoate)solid microneedle (MN) arrayssolvent-free micromoldingtransdermal drug delivery

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Area of Science:

  • Biomaterials Science
  • Drug Delivery Systems
  • Sustainable Manufacturing

Background:

  • Conventional microneedles (MNs) often use non-biodegradable materials, posing environmental challenges.
  • Developing sustainable alternatives for transdermal delivery devices is crucial for reducing waste and improving processing.
  • Poly(3-hydroxybutyrate-co-3-hydroxyvalerate-co-3-hydroxyhexanoate) (PHBHVHHx) is explored as a novel biopolyester for MN fabrication.

Purpose of the Study:

  • To assess the viability of PHBHVHHx for solvent-free fabrication of solid microneedle arrays.
  • To evaluate the mechanical properties, insertion capabilities, and drug delivery performance of PHBHVHHx microneedles.
  • To establish PHBHVHHx microneedles as a sustainable alternative to traditional transdermal systems.

Main Methods:

  • Solvent-free micromolding of PHBHVHHx at 200 °C to create microneedle arrays.
  • Morphological analysis using scanning electron microscopy.
  • Mechanical testing via axial compression and insertion evaluation using a Parafilm skin simulant.
  • In vitro drug release studies using diclofenac sodium and UV-Vis spectroscopy.

Main Results:

  • PHBHVHHx microneedles exhibited sharp conical shapes (681 ± 45 µm length) and micro-textured surfaces.
  • Microneedles demonstrated robust mechanical strength (0.25 ± 0.03 N/needle) and achieved insertion depths of approximately 396 µm.
  • Drug-coated microneedles showed rapid drug release, with ~73% diclofenac sodium released within 10 minutes.

Conclusions:

  • PHBHVHHx is a suitable biodegradable thermoplastic for fabricating solid microneedle arrays using a solvent-free method.
  • The fabricated PHBHVHHx microneedles possess adequate mechanical integrity and insertion capability.
  • These findings support the potential of PHBHVHHx microneedles as eco-friendly alternatives for transdermal drug delivery.