3D-Printing-Assisted Fabrication and Characterization of Pregabalin-Loaded PVA/PVP Dissolving Microneedle Arrays
Arjun Gokulan Manivannan1, Sreeja Balakrishna Pillai Suseela2, Mohana Priya Kandan2
1Department of Pharmacology, SRM College of Pharmacy, Faculty of Medicine and Health Sciences, SRM Institute of Science and Technology, Kattankulathur, Chengalpattu 603203, Tamil Nadu, India.
Micromachines
|June 26, 2026
Summary
This study developed pregabalin-loaded dissolving microneedles using 3D printing for enhanced transdermal drug delivery. The microneedles showed good mechanical properties and efficient drug release, indicating potential for improved patient treatment.
Area of Science:
- Materials Science
- Pharmaceutical Sciences
- Biomedical Engineering
Background:
- Transdermal drug delivery offers advantages over conventional routes but faces stratum corneum barrier challenges.
- Dissolving microneedles (DMNs) provide a minimally invasive method to enhance drug permeation and patient compliance.
- 3D printing facilitates precise fabrication and reproducibility of microneedle devices.
Purpose of the Study:
- To fabricate and characterize pregabalin-loaded polyvinyl alcohol/polyvinylpyrrolidone (PVA/PVP) dissolving microneedle arrays.
- To utilize a 3D-printing-assisted mold fabrication approach for efficient transdermal drug delivery.
- To evaluate the physicochemical and drug release properties of the developed DMNs.
Main Methods:
- Microneedle master molds were fabricated via 3D printing and replicated using polydimethylsiloxane (PDMS).
- Pregabalin-loaded bilayer microneedles were prepared using micromolding with PVA/PVP polymers.
- Characterization included SEM, mechanical testing, drug loading efficiency, FTIR, DSC, XRD, and in vitro drug release.
Main Results:
- Fabricated microneedles displayed uniform geometry, sharp tips, and no defects, with suitable rheological properties for mold filling.
- Microneedles demonstrated adequate mechanical strength (~3.3 N/needle) and successful insertion in a parafilm model.
- High drug loading efficiency (92.4%) and biphasic release (~96.8% cumulative release in 24 h) were observed, with polymer-drug compatibility confirmed.
Conclusions:
- A reproducible 3D-printing-assisted method for fabricating pregabalin-loaded DMNs was successfully established.
- The developed microneedle system possesses favorable mechanical, physicochemical, and drug release characteristics.
- These findings highlight the potential of the DMNs as an effective platform for transdermal drug delivery.