Systems, devices, and methods for analyte sensor applicators and low-friction photopolymerizable resin materials and method of making

Abstract

An assembly and method for delivering a sensor control device including an analyte sensor are disclosed. The assembly includes an applicator having a housing, a spring element, and a sharp. The housing may include a plurality of ledges and first and second contact areas. A proximal portion of the spring element includes a deformable portion and a grasping element. The deformable portion is configured to transition from an unbiased state to a biased state when a proximal force is applied to the grasping element. Application of a compression force to the first and second contact areas causes the ledges to disengage from the spring element, allowing the deformable portion to transition from the biased state to the unbiased state and advance the sensor control device from a proximal position to a distal position. A photocurable composition for vat photopolymerization is also disclosed. The composition includes a base resin, dispersed solid lubricant particles, and a surfactant to stabilize dispersion and reduce sedimentation, producing reduced friction when cured.

Description

DocketNo. A0130.0337.WO 15095WOO1 SYSTEMS, DEVICES, AND METHODS FOR ANALYTE SENSOR APPLICATORS AND LOW- FRICTION PHOTOPOL YMERIZABLE RESIN MATERIALS AND METHOD OF MAKINGCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Provisional Application Serial No.63 / 777,381, filed March 25, 2025, and U.S. Provisional Application Serial No. 63 / 764,111, filed February 27, 2025, which are hereby expressly incorporated by reference in its entirety for all purposes.FIELD

[0002] The subject matter described herein relates generally to systems, devices, and methods for inserting at least a portion of an analyte sensor in a subject, low-friction resin materials for use in vat photopolymerization (VPP), methods for preparing and polymerizing these resin materials, and solid materials such as may be produced by these methods.BACKGROUND

[0003] The detection and / or monitoring of analyte levels, such as glucose, ketones, lactate, oxygen, hemoglobin A1C, or the like, can be vitally important to the health of an individual having diabetes. Patients suffering from diabetes mellitus can experience complications including loss of consciousness, cardiovascular disease, retinopathy, neuropathy, and nephropathy. Diabetics are generally required to monitor their glucose levels to ensure that they are being maintained within a clinically safe range, and may also use this information to determine if and / or when insulin is needed to reduce glucose levels in their bodies, or when additional glucose is needed to raise the level of glucose in their bodies.

[0004] Growing clinical data demonstrates a strong correlation between the frequency of glucose monitoring and glycemic control. Despite such correlation, however, many individuals diagnosed with a diabetic condition do not monitor their glucose levels as frequently as they should due to a combination of factors including convenience, testing discretion, pain associated with glucose testing, and cost.

[0005] To increase patient adherence to a plan of frequent glucose monitoring, in vivo analyte monitoring systems can be utilized, in which a sensor control device may be worn on the body of an individual who requires analyte monitoring. To increase comfort and convenienceDocket No. A0130.0337.WO 15095WOO1 for the individual, the sensor control device may have a small form-factor, and can be assembled and applied by the individual with a sensor applicator. The application process includes inserting at least a portion of a sensor that senses a user’s analyte level in a bodily fluid located in a layer of the human body, using an applicator, such that the sensor comes into contact with a bodily fluid. The sensor control device may also be configured to transmit analyte data to another device, from which the individual or her health care provider (“HCP”) can review the data and make therapy decisions.

[0006] In addition to the convenience of sensor control devices, simple applicators with fewer components may also offer many benefits, ranging from cost-savings to enhanced user experience to environmental considerations. One advantage with respect to simple applicators, for example, is in the lower manufacturing costs associated with a streamlined design and reduced complexity. Lowering manufacturing costs not only makes the overall glucose monitoring system more affordable for consumers but also contributes to resource efficiency in the production process. Additionally, the simplicity of the applicator can ensure easy insertion, facilitate a user-friendly experience, and minimize the learning curve for users. The increased recyclability of such devices further aligns with sustainable practices, as fewer components can mean less material waste and a more straightforward disassembly process.

[0007] Vat polymerization printing (VPP) represents a significant advancement in additive manufacturing, utilizing photosensitive liquid resins that selectively cure upon exposure to light. State-of-the-art VPP technologies include masked stereolithography (MSLA), digital light processing (DLP), stereolithography (SLA), and continuous liquid interface production (CLIP), which offer varying degrees of resolution, speed, and build volume. Current research focuses on expanding the material palette beyond conventional acrylate and epoxy-based photopolymers to include biocompatible resins, ceramic-loaded suspensions, and high-temperature-resistant formulations. Process innovations include multi-material capabilities, real-time process monitoring with closed-loop feedback systems, and hybrid approaches combining VPP with other manufacturing techniques. The technology has found diverse applications across industries including biomedical (patient-specific implants, tissue engineering scaffolds), aerospace (lightweight components with complex geometries), automotive (functional prototypes and enduse parts), dental (custom aligners, crowns), and consumer products (customized goods). Challenges being addressed include reducing material costs, improving mechanical properties andDocket No. A0130.0337.WO 15095WOO1 long-term stability of printed parts, and developing more sustainable, bio-based resins with reduced environmental impact.

[0008] The integration of additive manufacturing technologies, particularly vat photopolymerization (VPP), in custom low-volume device fabrication offers unparalleled advantages in speed, accuracy, and design freedom. However, the tribological and mechanical performance of photopolymerized devices may raise critical concerns for certain applications, compared to traditional manufacturing methods like injection molding, directly impacting their efficacy in critical applications. For example, frictional forces experienced by additively manufactured devices may lead to wear, degradation, and potential failure, which in some applications may compromise safety and operational efficacy.

[0009] Thus, a need exists for new photo polymerizable compositions for VPP, and methods for making these compositions, that preserve or enhance the advantages of VPP and materials produced thereby while overcoming the limitations noted above and others related thereto.SUMMARY

[0010] The purpose and advantages of the disclosed subject matter will be set forth in and apparent from the description that follows, as well as will be learned by practice of the disclosed subject matter. Additional advantages of the disclosed subject matter will be realized and attained by the methods and systems particularly pointed out in the written description and claims hereof, as well as from the appended drawings.

[0011] To achieve these and other advantages and in accordance with the purpose of the disclosed subject matter, as embodied and broadly described, the disclosed subject matter is directed to an assembly for delivery of a sensor control device, wherein the assembly includes an applicator and a sensor control device. According to an aspect of the embodiments, the applicator includes a housing, a resilient element such as a spring element, and a sharp.According to another aspect of the embodiments, the sensor control device may be configured to be worn on skin of a user, and includes an analyte sensor (e.g., a glucose sensor) coupled with sensor electronics. Referring again to the applicator, according to the embodiments, the housing of the applicator may include a detent such as a ledge or a plurality of ledges, and may further include one or more contact areas, such as a first contact area and a second contact area. The spring element may be at least partially disposed within the housing. A proximal portion of the spring element may include a deformable portion and a grasping element. The sensor controlDocket No. A0130.0337.WO 15095WOO1 device may be releasably coupled with a distal end of the spring element. The deformable portion of the spring element may be configured to transition from an unbiased state to a biased state when a force in the proximal direction is applied to the grasping element. At least a portion of the spring element may be configured to engage with the plurality of ledges when the spring element is transitioned to the biased state, wherein the plurality of ledges is configured to retain the spring element in the biased state. Application of a compression force to the first contact area and the second contact area may cause the plurality of ledges to disengage from the at least a portion of the spring element, the deformable portion of the spring element to transition from the biased state to the unbiased state, and the sensor control device to advance from a proximal position to a distal position, which may be a delivered position, for example corresponding to an insertion position.

[0012] According to some embodiments, the spring element is removable from the housing of the applicator. In some embodiments, the housing and the spring element may comprise a circular cross-sectional area. In other embodiments, the housing and the spring element may comprise a rectangular cross-sectional area. In still other embodiments, the housing and the spring element may have an ovular cross-sectional area.

[0013] According to another aspect of some embodiments, the plurality of ledges comprises two ledges. In other embodiments, the plurality of ledges comprises four ledges. According to another aspect of some embodiments, the housing of the applicator comprises a polymer selected from the group of polypropylene and polycarbonate. According to some embodiments, the spring element comprises a polymer selected from the group consisting of polyethylene, polypropylene, polyvinyl chloride, polystyrene, and polyethylene terephthalate. According to some embodiments, the housing has a removable cap. According to some embodiments, the assembly is coupled with a removable protective cover. According to some embodiments, the analyte sensor is coupled with a protective cover. According to some embodiments, the analyte sensor is a glucose sensor. According to some embodiments, the first contact area and the second contact area are located on opposing sides of the housing. According to some embodiments, the distal end of the spring element is arranged to move in a proximal direction from a first (pre-armed) position to a second (armed) position when a force in the proximal direction is applied to the grasping element. According to some embodiments, the distal end of the spring element is arranged to advance in a distal direction from the second position to a thirdDocket No. A0130.0337.WG 15095WOO1 (fired) position, beyond the first position, when the deformable portion of the spring element transitions from the biased state to the unbiased state.

[0014] To achieve these and other advantages and in accordance with the purpose of the disclosed subject matter, as embodied and broadly described, a method for enhancing tribological performance of additively manufactured objects may include preparing a photocurable resin mixture by dispersing solid lubricant particles in a photocurable base resin, and in addition, adding a surfactant to the photocurable resin mixture to improve dispersion stability and reduce sedimentation of the solid lubricant particles. The method may further include loading the photocurable resin mixture into a vat photopolymerization (VPP) 3D printer; and fabricating an object by selectively curing portions of the photocurable resin mixture using the VPP 3D printer. In an aspect of the method, the fabricated object exhibits a substantially reduced coefficient of friction compared to an object fabricated from the photocurable base resin without the solid lubricant particles. For example, the reduction in coefficient of friction may be at least 10% (9 / 10).

[0015] In another aspect of the method, the solid lubricant particles may be, or may include, at least one of polytetrafluoroethylene (PTFE) and graphite. The solid lubricant particles may be present in an amount of approximately 2% by weight of the photocurable resin mixture. The photocurable base resin may be, or may include, photocurable acrylates. The surfactant may be, or may include, polyethylene glycol (PEG). In an aspect, the PEG may have a molecular weight of approximately 400 (PEG 400). The surfactant may be present in an amount of approximately 10% by weight of the photocurable resin mixture.

[0016] In another aspect of the method, preparing the photocurable resin mixture may include using a planetary vacuum mixer to disperse the solid lubricant particles in the photocurable base resin, prior to curing the resin by VPP. The parameters for VPP may be adjusted to compensate for altered properties of the photocurable resin mixture. For example, the exposure time may be substantially greater than for the unmodified base resin. The fabrication may include fabricating a medical device component requiring low friction surfaces, wherein the fabricated medical device component exhibits a reduction in static coefficient of friction substantially less than a geometrically identical component fabricated from the photocurable base resin without the solid lubricant particles, for example, at least 10% less. The reduction in friction coefficient may enable use of VPP to make components for critical applications, such asDocket No. A0130.0337.WO 15095WOO1 medical devices. For example, using the presently disclosed materials and methods, it may be possible to fabricate on-body devices used for glucose or other analyte monitoring. Such devices are worn on the patient’s body, and during installation / insertion optimal friction characteristics may be of concern. The present materials once cured and solidified by photopolymerization may be suitable for use in such on body devices, and in other devices where friction is an issue.

[0017] In another aspect of the disclosure, a photocurable composition for vat photopolymerization, may be, or may include, a photocurable base resin, solid lubricant particles dispersed within the photocurable base resin, and a surfactant that stabilizes the dispersion of the solid lubricant particles within the photocurable base resin and reduces sedimentation during storage. In an aspect, the composition, when cured, exhibits reduced coefficient of friction compared to the cured photocurable base resin without the solid lubricant particles. For example, the composition, when cured and tested against itself in a friction test, may exhibit a reduction in static coefficient of friction of at least 50% compared to the cured photocurable base resin without the solid lubricant particles. For further example, the composition, when cured and tested against itself in a friction test, exhibits a kinetic coefficient of friction of less than 0.15.

[0018] In another aspect of photocurable composition, the solid lubricant particles may be, or may include, at least one of polytetrafluoroethylene (PTFE) and graphite. The solid lubricant particles may be present in an amount of approximately 2% by weight of the photocurable resin mixture. The photocurable base resin may be, or may include, photocurable acrylates. The surfactant may be, or may include, polyethylene glycol (PEG). In an aspect, the PEG may have a molecular weight of approximately 400 (PEG 400). The surfactant may be present in an amount of approximately 10% by weight of the photocurable resin mixture.

[0019] In another aspect, the photocurable composition may be suitable for fabricating a medical device component using vat photopolymerization and that maintains photocuring characteristics substantially similar to the photocurable base resin without the solid lubricant particles. The medical device component may exhibit a coefficient of friction substantially less than exhibited by a geometrically identical component made from the photocurable base resin without the solid lubricant particles.

[0020] Other systems, devices, methods, features and advantages of the subject matter described herein will be or will become apparent to one with skill in the art upon examination of the following figures and detailed description. It is intended that all such additional systems,DocketNo. A0130.0337.WO 15095WOO1 devices, methods, features, and advantages be included within this description, be within the scope of the subject matter described herein, and be protected by the accompanying claims. Aspects of the embodiments are set out in the independent claims and preferred features are set out in the dependent claims. The preferred features of the dependent claims may be provided in combination in a single embodiment and preferred features of one aspect may be provided in conjunction with other aspects. In no way should the features of the example embodiments be construed as limiting the appended claims, absent express recitation of those features in the claims.BRIEF DESCRIPTION OF THE FIGURES

[0021] The details of the subject matter set forth herein, both as to its structure and operation, may be apparent by study of the accompanying figures, in which like reference numerals refer to like parts. The components in the figures are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the subject matter. Moreover, all illustrations are intended to convey concepts, where relative sizes, shapes and other detailed attributes may be illustrated schematically rather than literally or precisely.

[0022] FIG. 1 is a system overview of a sensor applicator, reader device, monitoring system, network, and remote system.

[0023] FIG. 2A is a block diagram depicting an example embodiment of a reader device.

[0024] FIGS. 2B and 2C are block diagrams depicting example embodiments of sensor control devices.

[0025] FIG. 3A is a side view depicting an example embodiment of an applicator for delivery of an analyte sensor in the pre-armed position.

[0026] FIG. 3B is a side view depicting an example embodiment of an applicator for delivery of an analyte sensor in the armed position.

[0027] FIG. 3C is a side view depicting an example embodiment of an applicator for delivery of an analyte sensor in the fired position.

[0028] FIGS. 4A-4C are cross-section views depicting example embodiments of an applicator for delivery of an analyte sensor.

[0029] FIG. 5 is a flow diagram depicting an example embodiment method for delivery of an analyte sensor.Docket No. A0130.0337.WO 15095WOO1

[0030] FIG. 6 shows prior art material samples compared to samples of novel material prepared using methods as described herein.

[0031] FIG. 7A is a diagram illustrating principles of measuring friction coefficients.

[0032] FIG. 7B is a chart illustrating static and kinetic friction.

[0033] FIG. 8A is a chart illustrating a measurement of static and kinetic friction coefficients for a base resin not containing any solid lubricant.

[0034] FIG. 8B is a chart illustrating a measurement of static and kinetic friction coefficients for another commercially available resin not containing any solid lubricant.

[0035] FIG. 8C is a chart illustrating a measurement of static and kinetic friction coefficients for the base resin containing a 2% PTFE solid lubricant.

[0036] FIG. 8D is a chart illustrating a measurement of static and kinetic friction coefficients for the base resin containing a 2% graphite solid lubricant.

[0037] FIG. 9 is a table comparing printing parameters for the base resin to printing parameters for the base reason including solid lubricant and surfactant additives.

[0038] FIG. 10 is a flow chart illustrating operations of a method for enhancing tribological performance of additively manufactured objects at least in part by preparing a resin with solid lubricants for vat photopolymerization (VPP).

[0039] FIG. 11 is a flow chart illustrating alternative or additional operations of the method for enhancing tribological performance of additively manufactured objects.

[0040] FIG. 12 is a flow chart illustrating alternative or additional operations of the method for enhancing tribological performance of additively manufactured objects.DETAILED DESCRIPTION

[0041] Before the present subject matter is described in detail, it is to be understood that this disclosure is not limited to the particular embodiments described, as such may, of course, vary. It is also to be understood that the terminology used herein is for the purpose of describing particular embodiments only, and is not intended to be limiting, since the scope of the present disclosure will be limited only by the appended claims.

[0042] As used herein and in the appended claims, the singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise.

[0043] The publications discussed herein are provided solely for their disclosure prior to the filing date of the present application. Nothing herein is to be construed as an admission that theDocket No. A0130.0337.WO 15095WOO1 present disclosure is not entitled to antedate such publication by virtue of prior disclosure.Further, the dates of publication provided may be different from the actual publication dates which may need to be independently confirmed.

[0044] Generally, embodiments of the present disclosure include systems, devices, and methods for the use of analyte sensor applicators for use with in vivo analyte monitoring systems. An applicator can be provided to the user in a sterile package with an electronics housing of the sensor control device contained therein. According to some embodiments, a structure separate from the applicator, such as a container, can also be provided to the user as a sterile package with a sensor module and a sharp module contained therein. The user can couple the sensor module to the electronics housing, and can couple the sharp to the applicator with an assembly process that involves the insertion of the applicator into the container in a specified manner. In other embodiments, the applicator, sensor control device, sensor module, and sharp module can be provided in a single package. The applicator can be used to position the sensor control device on a human body with a sensor in contact with the wearer’s bodily fluid. The embodiments provided herein are improvements to reduce the likelihood that a sensor is improperly inserted or damaged, or elicits an adverse physiological response. Other improvements and advantages are provided as well. The various configurations of these devices are described in detail by way of the embodiments which are only examples.

[0045] Furthermore, many embodiments include in vivo analyte sensors structurally configured so that at least a portion of the sensor is, or can be, positioned in the body of a user to obtain information about at least one analyte of the body. It should be noted, however, that the embodiments disclosed herein can be used with in vivo analyte monitoring systems that incorporate in vitro capability, as well as purely in vitro or ex vivo analyte monitoring systems, including systems that are entirely non-invasive.

[0046] Furthermore, for each and every embodiment of a method disclosed herein, systems and devices capable of performing each of those embodiments are covered within the scope of the present disclosure. For example, embodiments of sensor control devices are disclosed, and these devices can have one or more sensors, analyte monitoring circuits (e.g., an analog circuit), memories (e.g., for storing instructions), power sources, communication circuits, transmitters, receivers, processors and / or controllers (e.g., for executing instructions) that can perform any and all method steps or facilitate the execution of any and all method steps. These sensor controlDocket No. A0130.0337.WG 15095WOO1 device embodiments can be used and can be capable of use to implement those steps performed by a sensor control device from any and all of the methods described herein.

[0047] As mentioned, a number of embodiments of systems, devices, and methods are described herein that provide for the improved assembly and use of analyte sensor insertion devices for use with in vivo analyte monitoring systems. In particular, several embodiments of the present disclosure are designed to improve the method of sensor insertion with respect to in vivo analyte monitoring systems and, in particular, to minimize trauma to an insertion site during a sensor insertion process. Some embodiments, for example, include a powered sensor insertion mechanism configured to operate at a higher, controlled speed relative to a manual insertion mechanism, in order to reduce trauma to an insertion site. In other embodiments, an applicator having a compressible distal end can stretch and flatten the skin surface at the insertion site, and consequently, can reduce the likelihood of a failed insertion as a result of skin tenting. In still other embodiments, a sharp with an offset tip, or a sharp manufactured utilizing a plastic material or a coined manufacturing process can also reduce trauma to an insertion site. In sum, these embodiments can improve the likelihood of a successful sensor insertion and reduce the amount of trauma at the insertion site, to name a few advantages.

[0048] Before describing these aspects of the embodiments in detail, however, it is first desirable to describe examples of devices that can be present within, for example, an in vivo analyte monitoring system, as well as examples of their operation, all of which can be used with the embodiments described herein.

[0049] There are various types of in vivo analyte monitoring systems. “Continuous Analyte Monitoring” systems (or “Continuous Glucose Monitoring” systems), for example, can transmit data from a sensor control device to a reader device continuously without prompting, e.g., automatically according to a schedule. “Flash Analyte Monitoring” systems (or “Flash Glucose Monitoring” systems or simply “Flash” systems), as another example, can transfer data from a sensor control device in response to a scan or request for data by a reader device, such as with a Near Field Communication (NFC) or Radio Frequency Identification (RFID) protocol. In vivo analyte monitoring systems can also operate without the need for finger stick calibration.

[0050] In vivo analyte monitoring systems can be differentiated from “in vitro” systems that contact a biological sample outside of the body (or “ex vivo”) and that typically include a meterDocketNo. A0130.0337.WO 15095WOO1 device that has a port for receiving an analyte test strip carrying bodily fluid of the user, which can be analyzed to determine the user’s blood sugar level.

[0051] In vivo monitoring systems can include a sensor that, while positioned in vivo, makes contact with the bodily fluid of the user and senses the analyte levels contained therein. The sensor can be part of the sensor control device that resides on the body of the user and contains the electronics and power supply that enable and control the analyte sensing. The sensor control device, and variations thereof, can also be referred to as a “sensor control unit,” an “on-body electronics” device or unit, an “on-body” device or unit, or a “sensor data communication” device or unit, to name a few.

[0052] In vivo monitoring systems can also include a device that receives sensed analyte data from the sensor control device and processes and / or displays that sensed analyte data, in any number of forms, to the user. This device, and variations thereof, can be referred to as a “handheld reader device,” “reader device” (or simply a “reader”), “handheld electronics” (or simply a “handheld”), a “portable data processing” device or unit, a “data receiver,” a “receiver” device or unit (or simply a “receiver”), or a “remote” device or unit, to name a few. Other devices such as personal computers have also been utilized with or incorporated into in vivo and in vitro monitoring systems.Example Embodiment of In Vivo Analyte Monitoring System

[0053] FIG. 1 is a conceptual diagram depicting an example embodiment of an analyte monitoring system 100 that includes a sensor applicator 150, a sensor control device 102, and a reader device 120. Here, sensor applicator 150 can be used to deliver sensor control device 102 to a monitoring location on a user’s skin where a sensor 104 is maintained in position for a period of time by an adhesive patch 105. Sensor control device 102 is further described in FIGS.2B and 2C, and can communicate with reader device 120 via a communication path 140 using a wired or wireless technique. Example wireless protocols include Bluetooth, Bluetooth Low Energy (BLE, BTLE, Bluetooth SMART, etc.), Near Field Communication (NFC) and others. Users can monitor applications installed in memory on reader device 120 using screen 122 and input 121, and the device battery can be recharged using power port 123. While only one reader device 120 is shown, sensor control device 102 can communicate with multiple reader devices 120. Each of the reader devices 120 can communicate and share data with one another. More details about reader device 120 is set forth with respect to FIG. 2A below. Reader device 120DocketNo. A0130.0337.WO 15095WOO1 can communicate with local computer system 170 via a communication path 141 using a wired or wireless communication protocol. Local computer system 170 can include one or more of a laptop, desktop, tablet, phablet, smartphone, set-top box, video game console, or other computing device and wireless communication can include any of a number of applicable wireless networking protocols including Bluetooth, Bluetooth Low Energy (BTLE), Wi-Fi or others. Local computer system 170 can communicate via communications path 143 with a network 190 similar to how reader device 120 can communicate via a communications path 142 with network 190, by a wired or wireless communication protocol as described previously.Network 190 can be any of a number of networks, such as private networks and public networks, local area or wide area networks, and so forth. A trusted computer system 180 can include a server and can provide authentication services and secured data storage and can communicate via communications path 144 with network 190 by wired or wireless technique.Example Embodiment of Reader Device

[0054] FIG. 2A is a block diagram depicting an example embodiment of a reader device 120 configured as a smartphone. Here, reader device 120 can include a display 122, input component 121, and a processing core 206 including a communications processor 222 coupled with memory 223 and an applications processor 224 coupled with memory 225. Also included can be separate memory 230, RF transceiver 228 with antenna 229, and power supply 226 with power management module 238. Further, reader device 120 can also include a multi-functional transceiver 232 which can communicate over Wi-Fi, NFC, Bluetooth, BTLE, and GPS with an antenna 234. As understood by one of skill in the art, these components are electrically and communicatively coupled in a manner to make a functional device.Example Embodiments of Sensor Control Devices

[0055] FIGS. 2B and 2C are block diagrams depicting example embodiments of sensor control devices 102 having analyte sensors 104 and sensor electronics 160 (including analyte monitoring circuitry) that can have the majority of the processing capability for rendering endresult data suitable for display to the user. In FIG. 2B, a single semiconductor chip 161 is depicted that can be a custom application specific integrated circuit (ASIC). Shown within ASIC 161 are certain high-level functional units, including an analog front end (AFE) 162, power management (or control) circuitry 164, processor 166, and communication circuitry 168 (whichDocketNo. A0130.0337.WO 15095WOO1 can be implemented as a transmitter, receiver, transceiver, passive circuit, or otherwise according to the communication protocol). In this embodiment, both AFE 162 and processor 166 are used as analyte monitoring circuitry, but in other embodiments either circuit can perform the analyte monitoring function. Processor 166 can include one or more processors, microprocessors, controllers, and / or microcontrollers, each of which can be a discrete chip or distributed amongst (and a portion of) a number of different chips.

[0056] A memory 163 is also included within ASIC 161 and can be shared by the various functional units present within ASIC 161, or can be distributed amongst two or more of them. Memory 163 can also be a separate chip. Memory 163 can be volatile and / or non-volatile memory. In this embodiment, ASIC 161 is coupled with power source 172, which can be a coin cell battery, or the like. AFE 162 interfaces with in vivo analyte sensor 104 and receives measurement data therefrom and outputs the data to processor 166 in digital form, which in turn processes the data to arrive at the end-result glucose discrete and trend values, etc. This data can then be provided to communication circuitry 168 for sending, by way of antenna 171, to reader device 120 (not shown), for example, where minimal further processing is needed by the resident software application to display the data.

[0057] FIG. 2C is similar to FIG. 2B but instead includes two discrete semiconductor chips 162 and 174, which can be packaged together or separately. Here, AFE 162 is resident on ASIC 161. Processor 166 is integrated with power management circuitry 164 and communication circuitry 168 on chip 174. AFE 162 includes memory 163 and chip 174 includes memory 165, which can be isolated or distributed within. In one example embodiment, AFE 162 is combined with power management circuitry 164 and processor 166 on one chip, while communication circuitry 168 is on a separate chip. In another example embodiment, both AFE 162 and communication circuitry 168 are on one chip, and processor 166 and power management circuitry 164 are on another chip. It should be noted that other chip combinations are possible, including three or more chips, each bearing responsibility for the separate functions described, or sharing one or more functions for fail-safe redundancy.Example Embodiments of Systems and Methods for Delivery of an Analyte Sensor

[0058] Example embodiments of systems and methods for delivery of an analyte sensor, will now be described.DocketNo. A0130.0337.WO 15095WOO1

[0059] FIGS. 3A-3C are side views depicting an example embodiment of an applicator 300 for delivery of a sensor control device 102 comprising an analyte sensor 104, wherein the applicator 300 is shown, respectively, in the pre-armed position (FIG. 3A), armed position (FIG.3B), and the fired position (FIG. 3C). FIG. 3A depicts an example embodiment of applicator 300 for delivery of sensor control device 102 comprising an analyte sensor 104 in the pre-armed position. As shown in FIG. 3A, applicator 300 can have a housing 302, a spring element 305, and a sharp 308. According to one aspect of some embodiments, spring element 305 can be at least partially disposed within housing 302. In some embodiments, housing 302 can have two ledges 304A and 304B. In other embodiments, housing 302 can have three ledges, four ledges, or more ledges. In some embodiments, spring element 305 can be removable from housing 302. In many embodiments, spring element 305 can have a deformable portion 307 and a grasping element 306 located in a proximal portion of spring element 305. In some embodiments, in the pre-armed position, sensor control device 102 (including analyte sensor 104) is releasably coupled with a distal end of spring element 305. In some embodiments, sensor 104 can be a glucose sensor. As shown in FIG. 3A, in the pre-armed position, deformable portion 307 of spring element 305 is in an unbiased state.

[0060] In some embodiments, housing 302 can comprise a polymer selected from the group of polypropylene and polycarbonate. In some embodiments, spring element 305 can comprise a polymer selected from the group consisting of polyethylene, polypropylene, polyvinyl chloride, polystyrene, and polyethylene terephthalate. In some embodiments, spring element 305 can comprise a metal, such as iron, bronze, and titanium.

[0061] According to one aspect of certain embodiments, housing 302 can be formed from a photocurable composition suitable for vat photopolymerization, as described later in this application (see, e.g., FIGS. 6-12 and paragraphs

[0069] -

[0094] ). In certain embodiments, ledges 304A and 304B can include the photocurable composition. In some embodiments, the photocurable composition can include a photocurable base resin, solid lubricant particles dispersed within the photocurable base resin, and a surfactant that stabilizes the dispersion of the solid lubricant particles within the photocurable base resin and reduces sedimentation during storage. In many embodiments, when cured, the photocurable composition can exhibit reduced coefficient of friction compared to the cured photocurable base resin without the solid lubricant particles.DocketNo. A0130.0337.WO 15095WOO1

[0062] In some embodiments, forming the housing or the ledges from the disclosed low-friction photocurable composition can provide significant advantages during prototyping and low-volume production of the applicators. For example, when conventional stereolithography (SLA) resins are used, components may exhibit increased surface friction, leading to sticking edges, binding tabs, and inconsistent or rough disengagement behavior. Such frictional effects can require higher actuation forces and may misrepresent the intended performance of the final device, particularly where the production version is injection molded. By contrast, use of the disclosed photocurable composition, which exhibits a reduced coefficient of friction when cured, can enable small-batch inserters and prototype units to more closely replicate the functional behavior, actuation feel, and tactile response of injection-molded devices. This can be particularly beneficial for demonstration and training units, clinical pilot builds, human factors formative studies evaluating actuation force and ergonomics, and manufacturing validation samples assessing operator interaction and assembly feasibility.

[0063] FIG. 3B is a side view depicting an example embodiment of an applicator 300 for delivery of an analyte sensor in the armed position. As shown in FIG. 3B, when a force in the proximal direction, Fl, is applied to grasping element 306, deformable portion 307 of spring element 305 can change from the unbiased state to a biased state. In many embodiments, when deformable portion 307 is in the biased state, spring element 305 can engage with the ledges 304A and 304B. According to one aspect of some embodiments, ledges 304A and 304B are configured to engage deformable portion 307 of spring element 305 to prevent spring element 305 from returning to the unbiased state. In some embodiments, applicator 300 can be coupled with a removable cap. In other embodiments, applicator 300 can be coupled with a removable protective cover. In some embodiments, the analyte sensor 104 can be coupled with a protective cover.

[0064] FIG. 3C is a side view depicting an example embodiment of an applicator 300 for delivery of sensor control device 102 comprising an analyte sensor 104 in the fired position. As shown in FIG. 3C, when a compression force F2 (e.g., a squeezing force) is applied to contact areas 310A and 310B, housing 302 can deform, causing ledges 304A and 304B become disengaged from spring element 305. Consequently, spring element 305 is permitted to return to its unbiased state (see FIG. 3 A). When spring element 305 is returning to the unbiased state, sensor control device 102 with analyte sensor 104 are moved from a proximal position to a distal position toward the user’s skin (see skin surface ‘S’ in FIGS. 3A-3C). In many embodiments, the sharpDocketNo. A0130.0337.WO 15095WOO1 308 is configured to be displaced to an insertion position under the skin surface ‘S’ when spring element 305 returns to the unbiased state. In many embodiments, a portion of analyte sensor 104 is configured to penetrate the skin surface of the user and be positioned under the skin surface ‘S’ of the user. In some embodiments, first contact area 301 A and second contact area 30 IB are located on opposing sides of housing 302.

[0065] In some embodiments, applicator 300 can be removed from the skin surface ‘S’ of the user by applying a force in the proximal position after analyte sensor 104 is positioned. In some embodiments, the sharp 308 can be retracted by a second spring element. In some embodiments, a safety cap or shield can be provided to cover the exposed sharp.

[0066] FIGS. 4A-4C are cross-section views depicting example embodiments (410, 420, and 430) of an applicator for delivery of an analyte sensor. As shown in FIG. 4A, in some embodiments, housing 302 and spring element 305 can have a circular shape. In some embodiments, ledges 304A and 304B are diametrically opposed on the circular housing 302. In some documents, contact areas 310A and 310B are diametrically opposed on the circular housing 302. In some embodiments, contact areas 310A and 310B are perpendicular to the ledges 304A and 304B. As shown in FIG. 4B, in other embodiments, housing 302 and the spring element 305 can have a rectangular shape. In some embodiments, ledges 304 A and 304B are located on the opposite sides of the rectangular housing 302. In some embodiments, contact areas 310A and 310B are located on the opposite sides of the rectangular housing 302. In some embodiments, contact areas 310A and 310B are perpendicular to ledges 304A and 304B. As shown in FIG. 4C, in other embodiments, housing 302 and the spring element 305 can have an ovular shape. In some embodiments, the ovular housing 302 can four ledges, 304A, 304B, 304C, and 304D. In some embodiments, a line drawn between 304 A and 304C, and 304B and 304D may form a perpendicular intersection with the main axis of the ovular housing 302. In some documents, contact areas 310A and 310B are located on the two major axis endpoints on the ovular housing 302.

[0067] FIG. 5 is a flow diagram depicting an example embodiment method 500 for delivery of an analyte sensor. At step 510, an applicator is provided. In some embodiments, the applicator can include a sensor control device, a housing, a spring element, and a sharp. In some embodiments, the sensor control device can include sensor electronics coupled with the analyte sensor, and can be configured to be worn on skin of a user. In some embodiments, the housingDocketNo. A0130.0337.WO 15095WOO1 can include a plurality of ledges, and a first and a second contact area. In some embodiments, the spring element can be at least partially disposed within the housing, and a proximal portion of the spring element can include a deformable portion and a grasping element. At step 520, a force in the proximal direction is applied to the grasping element to cause the deformable portion of the spring element to change from an unbiased state to a biased state. At step 530, a compression force is applied to the first contact area and the second contact area to cause the plurality of ledges to disengage from the at least a portion of the spring element, the deformable portion of the spring element to transition from the biased state to the unbiased state, and the sensor control device to advance from a proximal position to a distal position.

[0068] In some embodiments, at least a portion of the spring element is configured to engage with the plurality of ledges when the spring element is transitioned to the biased state. In some embodiments, the plurality of ledges is configured to retain the spring element in the biased state. In some embodiments, the sensor control device is disposed in the applicator and releasably coupled with a distal end of the spring element when the deformable portion of the spring element is in the biased state. In some embodiments, the method further includes the step of removing a cap from the applicator. In other embodiments, the method further includes the step of removing a protective cover from the applicator. In other embodiments, the method further includes the step of removing a protective cover from the analyte sensor.Example Embodiments of Low -friction Photopolymerizable Resin Materials and Methods of Making

[0069] A common strategy for improving the tribological performance of polymeric materials is to compound them with solid lubricants. While such strategies have been successfully applied to different thermoplastic materials for injection molding, their application to photocurable acrylates used in VPP faces several challenges. These challenges include:

[0070] 1. Light scattering and absorption - Solid particles can interfere with the curing process by blocking or scattering the UV / visible light needed for polymerization, leading to incomplete curing and reduced mechanical properties.

[0071] 2. Dispersion stability - Achieving uniform distribution of solid lubricant particles throughout the resin without settling or agglomeration during printing is difficult.

[0072] 3. Viscosity management - Adding solid particles typically increases resin viscosity, which can complicate handling, recoating, and may require adjustments to printing parameters.DocketNo. A0130.0337.WO 15095WOO1

[0073] 4. Compatibility issues - Chemical compatibility between the lubricant particles and the resin matrix can affect adhesion and long-term stability.

[0074] The present disclosure proposes compositions and methods for overcoming these challenges, and discloses results of an investigation into the influence of solid lubricant additives, such as PTFE and graphite, on the tribological behavior of photocurable resins. First, formulations of commercially available photocurable resins and solid lubricants are developed, with surfactant added to improve stability as assessed by gravity sedimentation. Next, the empirically developed printing characteristics of these formulations are reported. In addition, the tribological performance of these additively manufactured formulations is evaluated and compared against unmodified resin. The addition of solid lubricants as disclosed herein can significantly improve the tribological behavior of photocurable resins, addressing crucial gaps in knowledge for optimizing the performance and reliability of medical device prototypes produced via additive manufacturing, and any other components having similar material requirements.

[0075] The resin-lubricant mixtures are prepared by dispersing polytetrafluoroethylene (PTFE) and / or graphite powders into the resin using a planetary vacuum mixer. The planetary vacuum mixer may use dual axis rotation to generate high shear forces that effectively deagglomerate the solid lubricant particles while simultaneously evacuating entrapped air to minimize void formation, thereby ensuring homogeneous distribution of the lubricant particles throughout the photocurable matrix without compromising the optical clarity required for efficient photopolymerization during the subsequent vat printing process. The addition of a surfactant, polyethylene glycol (PEG) having a molecular weight of approximately 400 (PEG 400), ensures uniform distribution of the solid lubricant particles and minimized sedimentation during storage. The compounded resins may be printed using a vat photopolymerization (VPP) 3D printer under optimized parameters as disclosed herein.

[0076] As shown in FIG. 6, specimens 600 were printed in prismatic geometries suitable for friction testing, which included rectangular flat surfaces to facilitate consistent contact during tribological evaluation. Specimen 601 is made from a photocurable acrylate without any additives, commercially available from BASF. Specimen 603 is made from the base resin of specimen 601, compounded with 2% by weight virgin PTFE dry lubricant powder, 3 micron average particle size, as solid lubricant and 10% by weight PEG 400 as surfactant. Specimen 604 is made from the base resin of specimen 601, compounded with 2% by weight 3000 mesh (5 micron average particleDocketNo. A0130.0337.WO 15095WOO1 size) pure graphite powder as solid lubricant and 10% by weight PEG 400 as surfactant. These custom compositions 602, 603 were also compared against a popular commercial resin (Formlabs White V4), shown as sample 602.

[0077] The coefficient of friction (p) was determined using an Instron universal testing machine 700 equipped with a friction testing module. Friction tests were conducted to evaluate the interaction between like materials, i.e., surfaces composed of the same resin formulation. As shown in FIG. 7A, the test involved sliding a printed specimen against an identical counterpart under controlled conditions. The pulling force required to move the specimen was measured, along with the applied normal force. The COF was calculated as the ratio of the measured pulling force to the normal force using the following equation:

[0078] coefficient of friction (p) = Pulling Force (Fp) / Normal Force (Fri)

[0079] FIG. 7B shows a representation of raw data typically provided by Instron testing, pointing out the measurement domain pertinent to static and kinetic testing. FIGS 8A-8B show representative test results from the specimens 601, 602, 603, and 604. FIG 8A shows Instron test results 800 for specimen 601. FIG 8B shows Instron test results 810 for specimen 602. FIG. 8C shows Instron test results 820 for specimen 603. FIG. 8D shows Instron test results 840 for specimen 604.

[0080] As can be seen by comparing the results 800, 810, 820, and 840, the addition of PTFE to the base resin resulted in a significant reduction in both static and kinetic friction. The static COF of the base resin was reduced by approximately 62.4%, dropping from 0.487 to 0.183. Similarly, the kinetic COF was reduced by 54%, from 0.265 to 0.122. This indicates that PTFE is highly effective in reducing friction, which aligns with its known properties as a solid lubricant. Similarly, the graphite-modified resin exhibited a static COF of 0.224, reduction of 54% compared to the base resin. The kinetic COF was the lowest among all formulations at 0.041, indicating exceptional tribological performance with minimal friction.

[0081] Overall, the results confirm that adding solid lubricants to photocurable resins can significantly improve their tribological performance. The PTFE-compounded resin demonstrated the most substantial reduction in both static and kinetic COF, making it a promising candidate for applications requiring low-friction surfaces. Further investigation into the long-term wear performance and mechanical integrity of these formulations may be helpful for validating their suitability for specific medical device applications.DocketNo. A0130.0337.WO 15095WOO1

[0082] Referring to Fig. 9, the Table 900 compares processing parameters between standard photocurable resin and photocurable resin containing solid lubricant additives reveals several significant differences indicative of the modifications beneficial for successful vat photopolymerization (VPP) of the modified composition. The table relates to masked stereolithography (MSLA), which is similar to SLA but instead of a laser, MSLA uses an LED screen as the light source. MSLA was used to prepare the specimens shown and described herein. Other VPP methods may also be suitable for preparing solid object from uncured resins as described herein, with processing parameter adjustments similar to those described herein.

[0083] The layer height parameter remains consistent at 0.100 mm across both formulations, demonstrating that the z-axis resolution capability is maintained despite the incorporation of solid lubricant particles into the photocurable matrix.

[0084] The bottom layer count increases from 4 layers in the standard resin to 5 layers in the resin with additives. The addition of a bottom layer may help ensure print stability and compensate for any reduced adhesion properties of the modified resin.

[0085] Exposure time 910 exhibits the most substantial parametric difference, increasing from 3.800 seconds for the standard resin to 50.000 seconds for the resin containing solid lubricant additives. This approximately thirteen-fold increase in exposure duration compensates for the optical interference properties of the solid lubricant particles, which attenuate light transmission through the resin and thereby reduce photopolymerization efficiency. Similarly, bottom exposure time increases from 30.000 seconds to 60.000 seconds when incorporating the solid lubricant additives. This doubling of exposure duration for initial layers facilitates sufficient curing at the build platform interface despite the aforementioned light attenuation effects.

[0086] The transition layer count decreases from 10 layers in the standard resin to 5 layers in the modified composition. This reduction may be advantageous due to the already extended exposure durations, wherein fewer intermediary transition steps are required to achieve optimal curing throughout the printed structure.

[0087] While both resins maintain a linear transition type, the transition layer interval time difference decreases from 2.38 seconds to 1.67 seconds in the modified resin, enabling a more rapid progression between exposure parameters despite the overall longer curing times.

[0088] The waiting mode during printing transitions from a “light off delay” methodology for the standard resin to a “resting time” approach for the resin with additives. Increasing the restingDocketNo. A0130.0337.WO 15095WOO1 time for modified resins may reduce layer delamination. In theory, increasing the resting time allows for better layer adhesion by giving excess resin time to settle between the layers and by enhancing oxygen dissipation which may be impacted by incorporating solid lubricants.

[0089] The modified resin employs specific rest time parameters, including an 8.000 second rest before lift, and 1.200 second intervals after both lift and retract operations. These temporal accommodations may facilitate resin flow and homogeneity maintenance, particularly important for compositions containing suspended particulate matter.

[0090] The parametric adjustments detailed herein demonstrate technical adaptations beneficial for successfully implementing solid lubricant additives in photocurable resins while maintaining print fidelity and structural integrity. Such modifications represent beneficial aspects of the processing methodology when utilizing these novel compositions in vat photopolymerization applications, including but not limited to VPP applications disclosed herein.

[0091] The compositions and techniques disclosed above may be used for enhancing tribological performance of additively manufactured objects. As shown in FIG. 10, a method 1000 for achieving this enhancement may include, at 1010, preparing a photocurable resin mixture by dispersing solid lubricant particles in a photocurable base resin. The method 1000 may further include, at 1020, adding a surfactant to the photocurable resin mixture to improve dispersion stability and reduce sedimentation of the solid lubricant particles. The method 1000 may further include, at 1030 loading the photocurable resin mixture into a vat photopolymerization (VPP) 3D printer. Although the illustrated specimens were produced using MSLA, other methods, for example SLA, DLP, or two-photon polymerization (TPP), may also be suitable. Optionally, print parameters as disclosed in connection with FIG. 9 may be used in the VPP process 1030. In an alternative, other print parameters or processes may be used to photopolymerize the composition to fabricate an object or component. At 1040, the method 1000 may include fabricating an object by selectively curing portions of the photocurable resin mixture using the VPP 3D printer. In an aspect of the method 1000, the fabricated object exhibits a substantially reduced coefficient of friction compared to an object fabricated from the photocurable base resin without the solid lubricant particles. For example, the reduction in coefficient of friction may be at least 10%, at least 20%, at least 30%, at least 40%, and least 50%, at least 60%, at least 70%, at least 80%, or at least 90%.DocketNo. A0130.0337.WO 15095WOO1

[0092] Referring to FIG. 11, additional or alternative elements 1100 of the method 1000 are illustrated. At 1110, the solid lubricant particles may be, or may include, at least one of polytetrafluoroethylene (PTFE) and graphite. Suitable powder forms may include, for example, virgin PTFE dry lubricant powder, 3 micron average particle size or 3000 mesh (5 micron average particle size) pure graphite powder. At 1120, the solid lubricant particles may be present in an amount of approximately 2% by weight of the photocurable resin mixture. At 1130, the surfactant may be, or may include, polyethylene glycol (PEG). In an aspect, the PEG may have a molecular weight of approximately 400 (PEG 400). At 1140, the surfactant may be present in an amount of approximately 10% by weight of the photocurable resin mixture, for example, approximately 5%, 7.5%, 10%, 12.5%, or 15% (i.e., within a range of about 5% to 15%. At 1150, the photocurable base resin may be, or may include, a photocurable acrylate.

[0093] Referring to FIG. 12, additional or alternative elements 1200 of the method 1000 are illustrated. At 1210, preparing the photocurable resin mixture may include using a planetary vacuum mixer to disperse the solid lubricant particles in the photocurable base resin, prior to curing the resin by VPP. The parameters for VPP may be adjusted to compensate for altered properties of the photocurable resin mixture, for example as described in connection with FIG. 9 above. In an aspect, the exposure time may be substantially greater than for the unmodified base resin. For example, at 1220, exposing the resin with a curing light may be performed with an exposure time of at least 40 seconds during the fabricating, or in alternatives, 2 to 20 times longer than the exposure time optimized for an unmodified base resin, all other things being equal. For further example, at 1230, the method may include bottom exposing the resin with the curing light for an exposure time of at least 50 seconds during the fabricating, or in alternatives, 20% to 100% longer than the exposure time optimized for an unmodified base resin, all other things being equal. Optimal time for top or bottom exposure will depend on the particle size of the lubricant and its concentration in the resin. Both factors will impact light attenuation and, consequently, alter the optimal exposure time.

[0094] At 1240, the fabricating 1040 may include fabricating a medical device component requiring low friction surfaces, wherein the fabricated medical device component exhibits a reduction in static coefficient of friction substantially less than a geometrically identical component fabricated from the photocurable base resin without the solid lubricant particles, forDocketNo. A0130.0337.WO 15095WOO1 example, at least 10% less, at least 20% less, at least 30% less, at least 40% less, at least 50% less, at least 60% less, at least 70% less, at least 80% less, or at least 90% less.

[0095] All essential characteristics of the photocurable composition for vat photopolymerization should be apparent based on the foregoing disclosure. For example, the composition includes a photocurable base resin, solid lubricant particles dispersed within the photocurable base resin, and a surfactant that stabilizes the dispersion of the solid lubricant particles within the photocurable base resin. The composition, when cured, exhibits reduced coefficient of friction compared to the cured photocurable base resin without the solid lubricant particles. Other characteristics of the composition, whether polymerized or not, should be clearly apparent from the foregoing disclosure. Further examples are omitted for the sake of brevity.

[0096] Exemplary embodiments and features are set out in the following numbered clauses:Clause 1. An assembly for insertion of an analyte sensor, the assembly comprising: a sensor control device configured to be worn on skin of a user, wherein the sensor control device comprises sensor electronics coupled with the analyte sensor; andan applicator comprising:a housing comprising:a plurality of ledges; anda first contact area and a second contact area;a spring element at least partially disposed within the housing, wherein a proximal portion of the spring element comprises a deformable portion and a grasping element, and wherein the sensor control device is releasably coupled with a distal end of the spring element; anda sharp;wherein the deformable portion of the spring element is configured to transition from an unbiased state to a biased state when a force in the proximal direction is applied to the grasping element,wherein at least a portion of the spring element is configured to engage with the plurality of ledges when the spring element is transitioned to the biased state, wherein the plurality of ledges is configured to retain the spring element in the biased state, andDocketNo. A0130.0337.WO 15095WOO1 wherein application of a compression force to the first contact area and the second contact area causes the plurality of ledges to disengage from the at least a portion of the spring element, the deformable portion of the spring element to transition from the biased state to the unbiased state, and the sensor control device to advance from a proximal position to a distal position.Clause 2. The assembly of clause 1, wherein the spring element is removable from the housing.Clause 3. The assembly of clauses 1-2, wherein the housing and the spring element comprise a circular cross-sectional area.Clause 4. The assembly of clauses 1-3, wherein the housing and the spring element comprise a rectangular cross-sectional area.Clause 5. The assembly of clauses 1-4, wherein the housing and the spring element comprise an ovular cross-sectional area.Clause 6. The assembly of clauses 1-5, wherein the plurality of ledges comprises two ledges.Clause 7. The assembly of clauses 1-6, wherein the plurality of ledges comprises four ledges.Clause 8. The assembly of clauses 1-7, wherein the housing comprises a polymer selected from the group of polypropylene and polycarbonate.Clause 9. The assembly of clauses 1-8, wherein the spring element comprises a polymer selected from the group consisting of polyethylene, polypropylene, polyvinyl chloride, polystyrene, and polyethylene terephthalate.DocketNo. A0130.0337.WO 15095WOO1 Clause 10. The assembly of clauses 1-9, wherein the assembly is coupled with a removable cap.Clause 11. The assembly of clauses 1-10, wherein the assembly is coupled with a removable protective cover.Clause 12. The assembly of clauses 1-11, wherein the analyte sensor is coupled with a protective cover.Clause 13. The assembly of clauses 1-12, wherein the analyte sensor is a glucose sensor.Clause 14. The assembly of clauses 1-13, wherein the first contact area and the second contact area are located on opposing sides of the housing.Clause 15. The assembly of clauses 1-14, wherein the distal end of the spring element is configured to move in a proximal direction from a first position to a second position when the force in the proximal direction is applied to the grasping element.Clause 16. The assembly of clause 15, wherein the distal end of the spring element is further configured to move in a distal direction from the second position to a third position when the deformable portion of the spring element transitions from the biased state to the unbiased state.Clause 17. The assembly of clauses 1-16, wherein the housing comprises a photocurable composition, wherein the photocurable composition comprises a photocurable base resin; solid lubricant particles dispersed within the photocurable base resin; and a surfactant that stabilizes the dispersion of the solid lubricant particles within the photocurable base resin and reduces sedimentation during storage, wherein the composition, when cured, exhibits reduced coefficient of friction compared to the cured photocurable base resin without the solid lubricant particles.DocketNo. A0130.0337.WO 15095WOO1 Clause 18. The assembly of clause 17, wherein the plurality of ledges comprise the photocurable composition.Clause 19. A method for delivery of an analyte sensor comprising:providing an applicator having a sensor control device configured to be worn on skin of a user, wherein the sensor control device comprises sensor electronics coupled with the analyte sensor, a sharp, a housing having a plurality of ledges and a first and a second contact area, and a spring element at least partially disposed within the housing, wherein a proximal portion of the spring element comprises a deformable portion and a grasping element, and wherein the sensor control device is releasably coupled with a distal end of the spring element;applying a force in the proximal direction to the grasping element to cause the deformable portion of the spring element to transition from an unbiased state to a biased state; andapplying a compression force to the first contact area and the second contact area to cause the plurality of ledges to disengage from the at least a portion of the spring element, the deformable portion of the spring element to transition from the biased state to the unbiased state, and the sensor control device to advance from a proximal position to a distal position;wherein at least a portion of the spring element is configured to engage with the plurality of ledges when the spring element is transitioned to the biased state, wherein the plurality of ledges is configured to retain the spring element in the biased state.Clause 20. The method of clause 19, further comprising removing a cap from the assembly.Clause 21. The method of clauses 19-20, further comprising removing a protective cover from the assembly.Clause 22. The method of clauses 19-21, further comprising removing a protective cover from the analyte sensor.DocketNo. A0130.0337.WO 15095WOO1 Clause 23. The method of clauses 19-22, wherein the analyte sensor is a glucose sensor.Clause 24. The method of clauses 19-23, wherein the housing comprises a polymer selected from the group of polypropylene and polycarbonate.Clause 25. The method of clauses 19-24, wherein the spring element comprises a polymer selected from the group consisting of polyethylene, polypropylene, polyvinyl chloride, polystyrene, and polyethylene terephthalate.Clause 26. The method of clauses 19-25, wherein applying the force in the proximal direction to the grasping element further causes the distal end of the spring element to move in a proximal direction from a first position to a second position.Clause 27. The method of clause 26, wherein applying the compression force to the first contact area and the second contact area further causes the distal end of the spring element to move in a distal direction from the second position to a third position.Clause 28. The method of clauses 19-27, wherein the housing comprises a photocurable composition, wherein the photocurable composition comprises a photocurable base resin; solid lubricant particles dispersed within the photocurable base resin; and a surfactant that stabilizes the dispersion of the solid lubricant particles within the photocurable base resin and reduces sedimentation during storage, wherein the composition, when cured, exhibits reduced coefficient of friction compared to the cured photocurable base resin without the solid lubricant particles.Clause 29. The method of clause 28, wherein the plurality of ledges comprise the photocurable composition.Clause 30. An assembly for insertion of an analyte sensor, the assembly comprising:a sensor control device configured to be worn on skin of a user; andDocketNo. A0130.0337.WO 15095WOO1 an applicator comprising:a housing comprising a plurality of ledges and a contact area;a spring element at least partially disposed within the housing, wherein a proximal portion of the spring element comprises a deformable portion and a grasping element, and wherein the sensor control device is releasably coupled with a distal end of the spring element; anda sharp;wherein the deformable portion of the spring element is configured to transition from an unbiased state to a biased state when a force in the proximal direction is applied to the grasping element,wherein at least a portion of the spring element is configured to engage with the plurality of ledges when the spring element is transitioned to the biased state, wherein the plurality of ledges is configured to retain the spring element in the biased state, and wherein application of a force to the contact area causes the plurality of ledges to disengage from the at least a portion of the spring element, the deformable portion of the spring element to transition from the biased state to the unbiased state, and the sensor control device to advance from a proximal position to a distal position.Clause 31. The assembly of clause 30, wherein the sensor control device comprises sensor electronics coupled with the analyte sensor.Clause 32. The assembly of clauses 30-31, wherein the contact area comprises a first contact area and a second contact area.Clause 33. The assembly of clause 32, wherein the first contact area and the second contact area are located on opposing sides of the housing.Clause 34. The assembly of clauses 30-33, wherein the force applied to the contact area is a compression force.DocketNo. A0130.0337.WO 15095WOO1 Clause 35. The assembly of clauses 30-34, wherein the analyte sensor is a glucose sensor.Clause 36. The assembly of clauses 30-35, wherein the housing comprises a photocurable composition, wherein the photocurable composition comprises a photocurable base resin; solid lubricant particles dispersed within the photocurable base resin; and a surfactant that stabilizes the dispersion of the solid lubricant particles within the photocurable base resin and reduces sedimentation during storage, wherein the composition, when cured, exhibits reduced coefficient of friction compared to the cured photocurable base resin without the solid lubricant particles.Clause 37. The assembly of clause 36, wherein the plurality of ledges comprise the photocurable composition.Clause 38. A method for delivery of an analyte sensor comprising:providing an applicator having a sensor control device configured to be worn on skin of a user, a sharp, a housing having a plurality of ledges and a contact area, and a spring element at least partially disposed within the housing, wherein a proximal portion of the spring element comprises a deformable portion and a grasping element, and wherein the sensor control device is releasably coupled with a distal end of the spring element;applying a force in the proximal direction to the grasping element to cause the deformable portion of the spring element to transition from an unbiased state to a biased state; andapplying a force to the first contact area and the second contact area to cause the plurality of ledges to disengage from the at least a portion of the spring element, the deformable portion of the spring element to transition from the biased state to the unbiased state, and the sensor control device to advance from a proximal position to a distal position;wherein at least a portion of the spring element is configured to engage with the plurality of ledges when the spring element is transitioned to the biased state, wherein the plurality of ledges is configured to retain the spring element in the biased state.DocketNo. A0130.0337.WO 15095WOO1 Clause 39. The method of clause 38, wherein the sensor control device comprises sensor electronics coupled with the analyte sensor.Clause 40. The method of clauses 38-39, wherein the contact area comprises a first contact area and a second contact area.Clause 41. The method of clauses 40, wherein the first contact area and the second contact area are located on opposing sides of the housing.Clause 42. The method of clauses 38-41, wherein the force applied to the contact area is a compression force.Clause 43. The method of clauses 38-42, wherein the analyte sensor is a glucose sensor.Clause 44. The method of clause 38-43, wherein the housing comprises a photocurable composition, wherein the photocurable composition comprises a photocurable base resin; solid lubricant particles dispersed within the photocurable base resin; and a surfactant that stabilizes the dispersion of the solid lubricant particles within the photocurable base resin and reduces sedimentation during storage, wherein the composition, when cured, exhibits reduced coefficient of friction compared to the cured photocurable base resin without the solid lubricant particles.Clause 45. The assembly of clause 44, wherein the plurality of ledges comprise the photocurable composition.Clause 46. A method for enhancing tribological performance of additively manufactured objects, the method comprising:preparing a photocurable resin mixture by dispersing solid lubricant particles in a photocurable base resin;DocketNo. A0130.0337.WO 15095WOO1 adding a surfactant to the photocurable resin mixture to improve dispersion stability and reduce sedimentation of the solid lubricant particles;loading the photocurable resin mixture into a vat photopolymerization (VPP) 3D printer; andfabricating an object by selectively curing portions of the photocurable resin mixture using the VPP 3D printer, wherein the fabricated object exhibits reduced coefficient of friction compared to an object fabricated from the photocurable base resin without the solid lubricant particles.Clause 47. The method of clause 46, wherein the solid lubricant particles comprise at least one of polytetrafluoroethylene (PTFE) and graphite.Clause 48. The method of clauses 46-47, wherein the surfactant comprises polyethylene glycol (PEG) having a molecular weight of approximately 400 (PEG 400).Clause 49. The method of clause 48, wherein the surfactant is present in an amount of approximately 10% by weight of the photocurable resin mixture.Clause 50. The method of clauses 46-49, wherein preparing the photocurable resin mixture comprises using a planetary vacuum mixer to disperse the solid lubricant particles in the photocurable base resin.Clause 51. The method of clauses 46-50, wherein the solid lubricant particles are present in an amount of approximately 2% by weight of the photocurable resin mixture.Clause 52. The method of clauses 46-51, wherein the photocurable base resin comprises photocurable acrylates.Clause 53. The method of clause 52, further comprising exposing the resin with a curing light for an exposure time of at least 40 seconds during the fabricating.DocketNo. A0130.0337.WO 15095WOO1 Clause 54. The method of clause 53, further comprising bottom exposing the resin with the curing light for an exposure time of at least 50 seconds during the fabricating.Clause 55. The method of clauses 46-54, wherein the fabrication comprises object is a medical device component requiring low friction surfaces, and wherein the component exhibits a reduction in static coefficient of friction of at least 50% compared to a geometrically identical component fabricated from the photocurable base resin without the solid lubricant particles.Clause 56. A photocurable composition for vat photopolymerization, comprising: a photocurable base resin;solid lubricant particles dispersed within the photocurable base resin; anda surfactant that stabilizes the dispersion of the solid lubricant particles within the photocurable base resin and reduces sedimentation during storage, wherein the composition, when cured, exhibits reduced coefficient of friction compared to the cured photocurable base resin without the solid lubricant particles.Clause 57. The photocurable composition of clause 56, wherein the photocurable base resin comprises photocurable acrylates.Clause 58. The photocurable composition of clauses 56-57, wherein the solid lubricant particles comprise at least one of polytetrafluoroethylene (PTFE) and graphite.Clause 59. The photocurable composition of clauses 56-58, wherein the surfactant comprises polyethylene glycol (PEG) having a molecular weight of approximately 400 (PEG 400).Clause 60. The photocurable composition of clause 59, wherein the solid lubricant particles are present in an amount of approximately 2% by weight of the composition.Clause 61. The photocurable composition of clauses 56-60, wherein the surfactant is present in an amount of approximately 10% by weight of the composition.DocketNo. A0130.0337.WO 15095WOO1 Clause 62. The photocurable composition of clauses 56-61, wherein the composition, when cured and tested against itself in a friction test, exhibits a reduction in static coefficient of friction of at least 50% compared to the cured photocurable base resin without the solid lubricant particles.Clause 63. The photocurable composition of clauses 56-62, wherein the composition, when cured and tested against itself in a friction test, exhibits a kinetic coefficient of friction of less than 0.15.Clause 64. The photocurable composition of clauses 56-63, wherein the photocurable composition is suitable for fabricating a medical device component using vat photopolymerization and maintains photocuring characteristics substantially similar to the photocurable base resin without the solid lubricant particles.Clause 65. The photocurable composition of clause 64, wherein the medical device component exhibits a coefficient of friction substantially less than exhibited by a geometrically identical component made from the photocurable base resin without the solid lubricant particles.

[0097] In summary, an assembly and method comprising an applicator for delivery of a sensor control device including an analyte sensor are disclosed, wherein the applicator includes a housing, a spring element, and a sharp. The sensor control device may include sensor electronics coupled with the analyte sensor, and may be configured to be worn on skin of a user. The housing may include a plurality of ledges, and a first and a second contact area. The spring element may be at least partially disposed within the housing, and a proximal portion of the spring element may include a deformable portion and a grasping element. The deformable portion of the spring element may be configured to transition from an unbiased state to a biased state when a force in the proximal direction is applied to the grasping element. At least a portion of the spring element may be configured to engage with the plurality of ledges when the spring element is transitioned to the biased state, wherein the plurality of ledges is configured to retain the spring element in the biased state. The sensor control device may be disposed in the applicator and releasably coupled with a distal end of the spring element when the deformableDocket No. A0130.0337.WO 15095WOO1 portion of the spring element is in the biased state. Application of a compression force to the first contact area and the second contact area may cause the plurality of ledges to disengage from the at least a portion of the spring element, the deformable portion of the spring element to transition from the biased state to the unbiased state, and the sensor control device to advance from a proximal position to a distal position.

[0098] In addition, in accordance with the foregoing, integration of solid lubricant additives into photocurable resins for vat photopolymerization substantially enhances the tribological performance of additively manufactured components. Such components may be useful for medical devices and any other devices where static or kinetic sliding friction is a concern. In contrast to the prior art, which has primarily concentrated on thermoplastic materials and conventional manufacturing methods, the present disclosure targets the critical need for improved performance in photocurable acrylates. Additionally, the lubricant-compounded photocurable acrylates disclosed herein exhibit stability, thereby enabling the scalability of these formulations for practical applications.

[0099] The description encompasses and expressly envisages methods that are non-surgical, non-invasive methods implemented outside the body. The methods are typically implemented by a user who is not required to be a medical professional.

[0100] It should be noted that all features, elements, components, functions, and steps described with respect to any embodiment provided herein are intended to be freely combinable and substitutable with those from any other embodiment. If a certain feature, element, component, function, or step is described with respect to only one embodiment, then it should be understood that that feature, element, component, function, or step can be used with every other embodiment described herein unless explicitly stated otherwise. This paragraph therefore serves as antecedent basis and written support for the introduction of claims, at any time, that combine features, elements, components, functions, and steps from different embodiments, or that substitute features, elements, components, functions, and steps from one embodiment with those of another, even if the following description does not explicitly state, in a particular instance, that such combinations or substitutions are possible. Thus, the foregoing description of specific embodiments of the disclosed subject matter has been presented for purposes of illustration and description. It is explicitly acknowledged that express recitation of every possible combinationDocketNo. A0130.0337.WO 15095WOO1 and substitution is overly burdensome, especially given that the permissibility of each and every such combination and substitution will be readily recognized by those of ordinary skill in the art.

[0101] While the embodiments are susceptible to various modifications and alternative forms, specific examples thereof have been shown in the drawings and are herein described in detail. It will be apparent to those skilled in the art that various modifications and variations can be made in the method and system of the disclosed subject matter without departing from the spirit or scope of the disclosed subject matter. Thus, it is intended that the disclosed subject matter include modifications and variations that are within the scope of the appended claims and their equivalents. Furthermore, any features, functions, steps, or elements of the embodiments may be recited in or added to the claims, as well as negative limitations that define the inventive scope of the claims by features, functions, steps, or elements that are not within that scope.

Claims

DocketNo. A0130.0337.WO 15095WOO1What is claimed is:

1. An assembly for insertion of an analyte sensor, the assembly comprising:a sensor control device configured to be worn on skin of a user, wherein the sensor control device comprises sensor electronics coupled with the analyte sensor; andan applicator comprising:a housing comprising:a plurality of ledges; anda first contact area and a second contact area;a spring element at least partially disposed within the housing, wherein a proximal portion of the spring element comprises a deformable portion and a grasping element, and wherein the sensor control device is releasably coupled with a distal end of the spring element; anda sharp;wherein the deformable portion of the spring element is configured to transition from an unbiased state to a biased state when a force in the proximal direction is applied to the grasping element,wherein at least a portion of the spring element is configured to engage with the plurality of ledges when the spring element is transitioned to the biased state, wherein the plurality of ledges is configured to retain the spring element in the biased state, andwherein application of a compression force to the first contact area and the second contact area causes the plurality of ledges to disengage from the at least a portion of the spring element, the deformable portion of the spring element to transition from the biased state to the unbiased state, and the sensor control device to advance from a proximal position to a distal position.

2. The assembly of claim 1, wherein the spring element is removable from the housing.DocketNo. A0130.0337.WO 15095WOO1 3. The assembly of claim 1, wherein the housing and the spring element comprise a circular cross-sectional area.

4. The assembly of claim 1, wherein the housing and the spring element comprise a rectangular cross-sectional area.

5. The assembly of claim 1, wherein the housing and the spring element comprise an ovular cross-sectional area.

6. The assembly of claim 1, wherein the plurality of ledges comprises two ledges.

7. The assembly of claim 1, wherein the plurality of ledges comprises four ledges.

8. The assembly of claim 1, wherein the housing comprises a polymer selected from the group of polypropylene and polycarbonate.

9. The assembly of claim 1, wherein the spring element comprises a polymer selected from the group consisting of polyethylene, polypropylene, polyvinyl chloride, polystyrene, and polyethylene terephthalate.

10. The assembly of claim 1, wherein the assembly is coupled with a removable cap.

11. The assembly of claim 1, wherein the assembly is coupled with a removable protective cover.

12. The assembly of claim 1, wherein the analyte sensor is coupled with a protective cover.

13. The assembly of claim 1, wherein the analyte sensor is a glucose sensor.DocketNo. A0130.0337.WO 15095WOO1 14. The assembly of claim 1, wherein the first contact area and the second contact area are located on opposing sides of the housing.

15. The assembly of claim 1, wherein the distal end of the spring element is configured to move in a proximal direction from a first position to a second position when the force in the proximal direction is applied to the grasping element.

16. The assembly of claim 15, wherein the distal end of the spring element is further configured to move in a distal direction from the second position to a third position when the deformable portion of the spring element transitions from the biased state to the unbiased state.

17. The assembly of claim 1, wherein the housing comprises a photocurable composition, wherein the photocurable composition comprises a photocurable base resin; solid lubricant particles dispersed within the photocurable base resin; and a surfactant that stabilizes the dispersion of the solid lubricant particles within the photocurable base resin and reduces sedimentation during storage, wherein the composition, when cured, exhibits reduced coefficient of friction compared to the cured photocurable base resin without the solid lubricant particles.

18. The assembly of claim 17, wherein the plurality of ledges comprise the photocurable composition.

19. A method for delivery of an analyte sensor comprising:providing an applicator having a sensor control device configured to be worn on skin of a user, wherein the sensor control device comprises sensor electronics coupled with the analyte sensor, a sharp, a housing having a plurality of ledges and a first and a second contact area, and a spring element at least partially disposed within the housing, wherein a proximal portion of the spring element comprises a deformable portion and a grasping element, and wherein the sensor control device is releasably coupled with a distal end of the spring element;applying a force in the proximal direction to the grasping element to cause the deformable portion of the spring element to transition from an unbiased state to a biased state; andDocketNo. A0130.0337.WO 15095WOO1 applying a compression force to the first contact area and the second contact area to cause the plurality of ledges to disengage from the at least a portion of the spring element, the deformable portion of the spring element to transition from the biased state to the unbiased state, and the sensor control device to advance from a proximal position to a distal position;wherein at least a portion of the spring element is configured to engage with the plurality of ledges when the spring element is transitioned to the biased state, wherein the plurality of ledges is configured to retain the spring element in the biased state.

20. The method of claim 19, further comprising removing a cap from the assembly.

21. The method of claim 19, further comprising removing a protective cover from the assembly.

22. The method of claim 19, further comprising removing a protective cover from the analyte sensor.

23. The method of claim 19, wherein the analyte sensor is a glucose sensor.

24. The method of claim 19, wherein the housing comprises a polymer selected from the group of polypropylene and polycarbonate.

25. The method of claim 19, wherein the spring element comprises a polymer selected from the group consisting of polyethylene, polypropylene, polyvinyl chloride, polystyrene, and polyethylene terephthalate.

26. The method of claim 19, wherein applying the force in the proximal direction to the grasping element further causes the distal end of the spring element to move in a proximal direction from a first position to a second position.DocketNo. A0130.0337.WO 15095WOO1 27. The method of claim 26, wherein applying the compression force to the first contact area and the second contact area further causes the distal end of the spring element to move in a distal direction from the second position to a third position.

28. The method of claim 19, wherein the housing comprises a photocurable composition, wherein the photocurable composition comprises a photocurable base resin; solid lubricant particles dispersed within the photocurable base resin; and a surfactant that stabilizes the dispersion of the solid lubricant particles within the photocurable base resin and reduces sedimentation during storage, wherein the composition, when cured, exhibits reduced coefficient of friction compared to the cured photocurable base resin without the solid lubricant particles.

29. The method of claim 28, wherein the plurality of ledges comprise the photocurable composition.

30. An assembly for insertion of an analyte sensor, the assembly comprising:a sensor control device configured to be worn on skin of a user; andan applicator comprising:a housing comprising a plurality of ledges and a contact area;a spring element at least partially disposed within the housing, wherein a proximal portion of the spring element comprises a deformable portion and a grasping element, and wherein the sensor control device is releasably coupled with a distal end of the spring element; anda sharp;wherein the deformable portion of the spring element is configured to transition from an unbiased state to a biased state when a force in the proximal direction is applied to the grasping element,wherein at least a portion of the spring element is configured to engage with the plurality of ledges when the spring element is transitioned to the biased state, wherein the plurality of ledges is configured to retain the spring element in the biased state, andwherein application of a force to the contact area causes the plurality of ledges to disengage from the at least a portion of the spring element, the deformable portion of the springDocketNo. A0130.0337.WO 15095WOO1 element to transition from the biased state to the unbiased state, and the sensor control device to advance from a proximal position to a distal position.

31. The assembly of claim 30, wherein the sensor control device comprises sensor electronics coupled with the analyte sensor.

32. The assembly of claim 30, wherein the contact area comprises a first contact area and a second contact area.

33. The assembly of claim 32, wherein the first contact area and the second contact area are located on opposing sides of the housing.

34. The assembly of claim 30, wherein the force applied to the contact area is a compression force.

35. The assembly of claim 30, wherein the analyte sensor is a glucose sensor.

36. The assembly of claim 30, wherein the housing comprises a photocurable composition, wherein the photocurable composition comprises a photocurable base resin; solid lubricant particles dispersed within the photocurable base resin; and a surfactant that stabilizes the dispersion of the solid lubricant particles within the photocurable base resin and reduces sedimentation during storage, wherein the composition, when cured, exhibits reduced coefficient of friction compared to the cured photocurable base resin without the solid lubricant particles.

37. The assembly of claim 36, wherein the plurality of ledges comprise the photocurable composition.

38. A method for delivery of an analyte sensor comprising:providing an applicator having a sensor control device configured to be worn on skin of a user, a sharp, a housing having a plurality of ledges and a contact area, and a spring element at least partially disposed within the housing, wherein a proximal portion of the spring elementDocketNo. A0130.0337.WO 15095WOO1 comprises a deformable portion and a grasping element, and wherein the sensor control device is releasably coupled with a distal end of the spring element;applying a force in the proximal direction to the grasping element to cause the deformable portion of the spring element to transition from an unbiased state to a biased state; andapplying a force to the first contact area and the second contact area to cause the plurality of ledges to disengage from the at least a portion of the spring element, the deformable portion of the spring element to transition from the biased state to the unbiased state, and the sensor control device to advance from a proximal position to a distal position;wherein at least a portion of the spring element is configured to engage with the plurality of ledges when the spring element is transitioned to the biased state, wherein the plurality of ledges is configured to retain the spring element in the biased state.

39. The method of claim 38, wherein the sensor control device comprises sensor electronics coupled with the analyte sensor.

40. The method of claim 39, wherein the contact area comprises a first contact area and a second contact area.

41. The method of claim 40, wherein the first contact area and the second contact area are located on opposing sides of the housing.

42. The method of claim 38, wherein the force applied to the contact area is a compression force.

43. The method of claim 38, wherein the analyte sensor is a glucose sensor.

44. The method of claim 38, wherein the housing comprises a photocurable composition, wherein the photocurable composition comprises a photocurable base resin; solid lubricant particles dispersed within the photocurable base resin; and a surfactant that stabilizes the dispersion of the solid lubricant particles within the photocurable base resin and reducesDocketNo. A0130.0337.WO 15095WOO1 sedimentation during storage, wherein the composition, when cured, exhibits reduced coefficient of friction compared to the cured photocurable base resin without the solid lubricant particles.

45. The assembly of claim 44, wherein the plurality of ledges comprise the photocurable composition.

46. A method for enhancing tribological performance of additively manufactured objects, the method comprising:preparing a photocurable resin mixture by dispersing solid lubricant particles in a photocurable base resin;adding a surfactant to the photocurable resin mixture to improve dispersion stability and reduce sedimentation of the solid lubricant particles;loading the photocurable resin mixture into a vat photopolymerization (VPP) 3D printer; andfabricating an object by selectively curing portions of the photocurable resin mixture using the VPP 3D printer, wherein the fabricated object exhibits reduced coefficient of friction compared to an object fabricated from the photocurable base resin without the solid lubricant particles.

47. The method of claim 46, wherein the solid lubricant particles comprise at least one of polytetrafluoroethylene (PTFE) and graphite.

48. The method of claim 46, wherein the surfactant comprises polyethylene glycol (PEG) having a molecular weight of approximately 400 (PEG 400).

49. The method of claim 48, wherein the surfactant is present in an amount of approximately 10% by weight of the photocurable resin mixture.

50. The method of claim 46, wherein preparing the photocurable resin mixture comprises using a planetary vacuum mixer to disperse the solid lubricant particles in the photocurable base resin.DocketNo. A0130.0337.WO 15095WOO1 51. The method of claim 46, wherein the solid lubricant particles are present in an amount of approximately 2% by weight of the photocurable resin mixture.

52. The method of claim 46, wherein the photocurable base resin comprises photocurable acrylates.

53. The method of claim 52, further comprising exposing the resin with a curing light for an exposure time of at least 40 seconds during the fabricating.

54. The method of claim 53, further comprising bottom exposing the resin with the curing light for an exposure time of at least 50 seconds during the fabricating.

55. The method of claim 46, wherein the fabrication comprises object is a medical device component requiring low friction surfaces, and wherein the component exhibits a reduction in static coefficient of friction of at least 50% compared to a geometrically identical component fabricated from the photocurable base resin without the solid lubricant particles.

56. A photocurable composition for vat photopolymerization, comprising:a photocurable base resin;solid lubricant particles dispersed within the photocurable base resin; anda surfactant that stabilizes the dispersion of the solid lubricant particles within the photocurable base resin and reduces sedimentation during storage, wherein the composition, when cured, exhibits reduced coefficient of friction compared to the cured photocurable base resin without the solid lubricant particles.

57. The photocurable composition of claim 56, wherein the photocurable base resin comprises photocurable acrylates.

58. The photocurable composition of claim 56, wherein the solid lubricant particles comprise at least one of polytetrafluoroethylene (PTFE) and graphite.DocketNo. A0130.0337.WO 15095WOO1 59. The photocurable composition of claim 56, wherein the surfactant comprises polyethylene glycol (PEG) having a molecular weight of approximately 400 (PEG 400).

60. The photocurable composition of claim 59, wherein the solid lubricant particles are present in an amount of approximately 2% by weight of the composition.

61. The photocurable composition of claim 56, wherein the surfactant is present in an amount of approximately 10% by weight of the composition.

62. The photocurable composition of claim 56, wherein the composition, when cured and tested against itself in a friction test, exhibits a reduction in static coefficient of friction of at least 50% compared to the cured photocurable base resin without the solid lubricant particles.

63. The photocurable composition of claim 56, wherein the composition, when cured and tested against itself in a friction test, exhibits a kinetic coefficient of friction of less than 0.15.

64. The photocurable composition of claim 56, wherein the photocurable composition is suitable for fabricating a medical device component using vat photopolymerization and maintains photocuring characteristics substantially similar to the photocurable base resin without the solid lubricant particles.

65. The photocurable composition of claim 64, wherein the medical device component exhibits a coefficient of friction substantially less than exhibited by a geometrically identical component made from the photocurable base resin without the solid lubricant particles.

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