Dissolvable Microneedle Arrays With Micromilled Molds for Dosage Control
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Solution Overview
Problem
Conventional microneedle-array based transdermal drug delivery systems face limitations in controlling dosage, quantity, and complexity in fabrication and testing, particularly in creating geometric features and materials for efficient bioactive molecule delivery.
Innovation Solution
The development of dissolvable microneedle arrays using micromilling techniques for producing mastermolds and spin-casting bioactive components, enabling flexible, rapid, and cost-effective production with precise control over microneedle geometry and bioactive delivery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional lithographic and laser etching technologies are used to create mastermolds, then geometric features and material precision are improved, but fabrication complexity and cost increase significantly
Solution Approach 1:
The patent replaces complex lithographic and laser-based fabrication systems with a micromolding system that uses a simple mastermold. The mastermold is created once using conventional techniques, then used to produce multiple microneedle arrays through a straightforward molding process, eliminating the need for repeated complex lithographic and laser etching operations.
Solution Approach 2:
The patent creates a mastermold that serves as a template for producing multiple production molds, which in turn generate numerous microneedle arrays. This copying approach allows precise geometric features to be replicated across many units without repeating the complex fabrication process for each individual array.
2Quantity of substance
If hollow microneedles with reservoirs are used, then delivery quantity and precision are improved, but device complexity and fabrication difficulty increase
Solution Approach 1:
The patent combines the microneedle structure with the drug reservoir into a single integrated solid microneedle array. The bioactive components are incorporated directly into the microneedle material matrix, eliminating the need for separate hollow reservoirs and complex attachment mechanisms while maintaining controlled delivery capability.
Solution Approach 2:
The patent uses composite materials where bioactive components are embedded within the microneedle structure itself. This integration allows the microneedles to function both as structural elements for skin penetration and as reservoirs for drug delivery, simplifying the overall device architecture.
3Manufacturing precision
If surface-coated solid microneedles are used, then dosage control is improved, but delivered quantity is limited
Solution Approach 1:
The patent changes the parameter of drug incorporation from surface coating to bulk integration. By incorporating bioactive components throughout the entire microneedle volume rather than just on the surface, the system maintains precise dosage control through material composition while dramatically increasing the total drug payload capacity.
4Ease of manufacture
If dissolvable microneedle arrays are used, then ease of manufacture and storage are improved, but manufacturing precision and geometric control were previously limited
Solution Approach 1:
The patent uses a mastermold that precisely defines the desired microneedle geometry. This mastermold is then used to create production molds that replicate the precise geometric features across many microneedle arrays, maintaining high manufacturing precision while keeping the fabrication process simple and suitable for dissolvable materials.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach allows for efficient, precise, and reproducible delivery of bioactive molecules to the skin, minimizing pain and bleeding, and enabling simultaneous delivery of antigens and adjuvants, with stable storage and distribution capabilities, making it suitable for broad clinical deployment.
Implementation Method 1
micromilling a mastermold to create a female production mold
Implementation Method 2
spin-casting material (including bioactive components) into the production mold
Implementation Method 3
dissolvable microneedle arrays that can provide efficient, precise, and reproducible delivery of biologically active molecules
Data Source
AI summary
A method of forming a microneedle array can include forming a sheet of material having a plurality of layers and micromilling the sheet of material to form a microneedle array. At least one of the plurality of layers can include a bioactive component, and the microneedle array can include a base portion and plurality of microneedles extending from the base portion.