Microneedle 3D Screen Printing Layer-by-Layer
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Solution Overview
Problem
Existing methods for manufacturing microneedles are limited by high material consumption, waste, and limited flexibility in production volume and material selection, making them unsuitable for large-scale production and diverse applications.
Innovation Solution
A method utilizing 3D screen printing to produce microneedles layer by layer, allowing for high-volume production with minimal effort and greater flexibility in material composition and shape, including the option of producing the needle and support structure in one piece or separately, and enabling precise control over active ingredient delivery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional manufacturing methods (micromolding, lithography, droplet-born airblowing, electrospun pillar array) are used to produce microneedles, then microneedles can be manufactured, but the production volume is limited and material stress occurs due to high processing temperatures
Solution Approach 1:
The patent changes the manufacturing parameters by using 3D screen printing with lower processing temperatures compared to traditional methods. The printing process uses a printing head that deposits material layer by layer at controlled temperatures, avoiding the high temperature stress associated with conventional micromolding and lithography methods, while enabling high-volume production through automated layer-by-layer construction
Solution Approach 2:
The patent replaces traditional mechanical manufacturing systems (micromolding, lithography, electrospinning) with a 3D screen printing system that uses a printing head to deposit material layer by layer. This substitution allows for more precise control of material deposition, reduced thermal stress, and scalable production volumes through automated control of the printing process
2Productivity
If casting processes are used to manufacture microneedles, then microneedles can be produced, but material consumption and waste increase due to sprue structures
Solution Approach 1:
The patent segments the microneedle manufacturing into discrete layer-by-layer deposition steps using 3D screen printing. Each layer is printed precisely where needed, eliminating the need for sprue structures and waste removal operations inherent in casting processes. The layer-by-layer approach allows for additive manufacturing that builds only the required material, significantly reducing material consumption and waste
Solution Approach 2:
The patent changes the manufacturing approach from subtractive or form-based casting to additive layer-by-layer printing. This parameter change in the manufacturing process fundamentally eliminates sprue structures and associated material waste, while maintaining production efficiency through automated layer deposition and reducing material consumption through precise control of material application
3Adaptability or versatility
If traditional manufacturing methods are used, then microneedles can be produced, but flexibility in material selection and substrate material choice is limited
Solution Approach 1:
The patent changes the manufacturing parameters to enable greater material flexibility. The 3D screen printing process can accommodate various material types (polymers, metals, ceramics, biocompatible materials) by adjusting printing parameters such as temperature, deposition speed, and material viscosity. This allows selection of optimal materials for specific applications without being constrained by the manufacturing process, while the layer-by-layer approach keeps the process manageable through controlled deposition parameters
4Productivity
If 3D screen printing is used to produce microneedles layer by layer, then high-volume production is enabled with reduced material waste, but drying steps between layers are required
Solution Approach 1:
The patent implements continuous layer-by-layer printing with integrated drying steps. The printing process continues without interruption through automated layer deposition, and drying occurs continuously or in rapid sequences between layers. This continuous operation maintains high production volume while managing drying time through efficient process integration, ensuring each layer is properly dried before the next layer is deposited to maintain structural integrity
Solution Approach 2:
The patent optimizes drying parameters between layers to minimize time loss. By controlling drying temperature, humidity, and timing parameters, the process achieves rapid drying between layers without significantly impacting production volume. The layer-by-layer printing allows for optimized drying cycles that balance material curing requirements with production speed, maintaining high productivity while reducing overall manufacturing time
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 efficient, high-volume production of microneedles with reduced material waste and temperature stress, allowing for precise drug delivery and dosage, and flexibility in design for various applications.
Implementation Method 1
at least one needle structure arranged on the support structure for penetrating the stratum corneum of human and/or animal skin is produced layer by layer by 3D screen printing
Implementation Method 2
drying steps are carried out between individual steps for the layer-by-layer production of the needle structure, by which drying of the respective pre-printed layer is ensured
Data Source
Figure 1
Figure 2
Figure 3a
AI summary
Microneedle (10), in particular for transdermal and/or intradermal drug delivery, with a support structure (12) and with at least one needle structure (14) arranged on the support structure for penetrating the stratum corneum of human and/or animal skin, characterized in that at least the needle structure is produced by additive manufacturing, in particular 3D screen printing.