Electrohydrodynamic Printing for Microneedle Patch Manufacturing

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Solution Overview

Problem

Conventional microneedle manufacturing methods face challenges in producing high-aspect-ratio microneedles with precise control over size and structure, leading to difficulties in skin penetration and bioactive substance delivery, and existing methods are painful and difficult to scale for narrow arrangements.

Innovation Solution

A microneedle manufacturing apparatus using electrohydrodynamic printing technology, which includes a substrate, a nozzle unit for biocompatible ink discharge, a power unit for controlling ink deposition, and a controller for precise control of ink size, interval, and electric field to form sharp-tipped microneedles with multi-layer structures.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If conventional needle injection is used, then drug delivery is effective, but it causes great pain and trauma

Engineering Contradiction:

Improvepain and traumaVSAvoiddrug delivery effectiveness

Core Design Contradiction:

Object-affected harmful factorsVSReliability

Solution Approach 1:

The invention changes the physical parameters of the needle by reducing its dimensions. Microneedles with lengths of 0.5-2 mm and diameters of 10-100 μm are used instead of conventional needles, allowing painless penetration through the stratum corneum while maintaining drug delivery capability through dissolution in the skin

Inventive Principle:

Principle #35Parameter changes

2Ease of manufacture

If microneedles are made by injecting material into a mold, then manufacturing is simple, but it is difficult to manufacture micro molds suitable for needle size and maintenance is difficult

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidmicro mold fabrication difficulty

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The invention replaces the mechanical molding process with a chemical deposition process. Material is deposited layer by layer through electrohydrodynamic printing, eliminating the need for complex micro molds and their associated fabrication and maintenance challenges

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Ease of manufacture

If a tensile method is used to manufacture microneedles, then manufacturing is possible, but it causes pain when attached to skin and has difficulty in forming narrow arrangements

Engineering Contradiction:

Improvemanufacturing feasibilityVSAvoidarrangement precision and narrow spacing

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The invention segments the manufacturing process into controlled deposition steps, creating each microneedle individually through electrohydrodynamic printing. This allows precise positioning and narrow spacing between needles while maintaining structural integrity, avoiding the pain and positioning difficulties of tensile methods

Inventive Principle:

Principle #1Segmentation

4Length of moving object

If high-aspect-ratio microneedles are manufactured, then skin penetration capability is improved, but manufacturing precision and sharp tip formation become difficult

Engineering Contradiction:

Improvemicroneedle length for skin penetrationVSAvoidsharp tip formation accuracy

Core Design Contradiction:

Length of moving objectVSManufacturing precision

Solution Approach 1:

The invention uses periodic deposition of material layers through controlled electrohydrodynamic printing. By depositing material in repeated cycles and removing support structures between layers, sharp tips with high aspect ratios are formed with precise control over geometry and dimensions

Inventive Principle:

Principle #19Periodic action

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

Enables the precise and high-resolution manufacturing of microneedles with controlled sharp tips and multi-layer structures, enhancing skin penetration and bioactive substance delivery while minimizing pain and manufacturing complexity.

Implementation Method 1

microneedle manufacturing apparatus using electrohydrodynamic printing

Methodology Applied

Scientific EffectElectrohydrodynamic printing: Electrohydrodynamics

Implementation Method 2

a power unit supplying power to the nozzle unit, and a controller controlling the power unit so that the ink is dropped from the nozzle unit

Methodology Applied

Scientific EffectElectric field control: Electric Field

Data Source

PatentUS20230137929A1Apparatus and method for manufacturing microneedle patch using electrohydrodynamic printing

Publication Date: 2023.05.04 FEROKA INC

AI summary

An apparatus and method for manufacturing microneedle using electrohydrodynamic printing are provided. The apparatus includes a substrate on which a printed microneedle is placed, a nozzle unit receiving a base material, which is a biocompatible material, as ink and discharging the ink to the substrate, a power unit supplying power to the nozzle unit, and a controller controlling the power unit so that the ink is dropped from the nozzle unit.