Microneedle Manufacturing via Deposition and Solidification
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Solution Overview
Problem
Existing methods for manufacturing microneedles are time-consuming and require expensive facilities, with moulding techniques facing challenges such as limited quality and difficulty in producing high aspect ratio needles that are difficult to fill and release.
Innovation Solution
A method involving the deposition of a substance onto a surface to form a solid needle-like shape, using sequential deposition of droplets or portions, and moving surfaces relative to each other to create needle-like structures, which can be automated and inexpensive, using materials like polymers or metals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If moulding techniques are used to manufacture microneedles, then production can be automated, but the quality is limited by the master quality and mould lifetime, and high aspect ratio needles are difficult to fill and release
Solution Approach 1:
The patent uses a master microneedle array to create a mould that replicates the needle geometry. The mould is then used to produce multiple copies of microneedles, maintaining high precision through the copying process while enabling automated production. This resolves the contradiction by using copying to preserve quality while achieving automation.
2Manufacturing precision
If photolithography is used to produce microneedles, then precise control over shape and size can be achieved, but the process is time-consuming and requires expensive facilities
Solution Approach 1:
The patent changes the physical state parameter of the material from solid to liquid or paste form, allowing the microneedles to be formed by deposition and solidification rather than by time-consuming photolithographic etching. This enables rapid production while maintaining precision through controlled deposition parameters.
Solution Approach 2:
The patent replaces the complex photolithography system with a simpler deposition and solidification process. Instead of using light patterns and chemical etching, the microneedles are formed by depositing material that then solidifies into the desired shape, dramatically reducing production time and facility requirements.
3Manufacturing precision
If etching techniques or laser machining are used, then microneedles can be produced with good precision, but the methods are time-consuming and require expensive facilities
Solution Approach 1:
The patent performs preliminary action by depositing the material in the desired microneedle shape before solidification. This pre-forming approach eliminates the need for subsequent time-consuming etching or machining operations, as the needles are already shaped before the material hardens.
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 method enables rapid and cost-effective production of microneedles with precise control over shape and size, minimizing pain by not penetrating the dermal layer, and allowing for the delivery of pharmaceuticals through the skin effectively.
Implementation Method 1
If the first portion or droplet is deposited in non-solid form, then it is preferred that the first portion or droplet is at least partially solidified prior to the deposition of the second or droplet of substance
Implementation Method 2
The step of forming a solid from the substance may, for example, include exposure of the substance to ultraviolet radiation to form a solid polymer
Data Source
AI summary
A method of manufacturing microneedles is provided, the method includes (i) depositing a substance onto a first surface and (ii) forming a solid needle-like shape from the substance. The substance may be deposited in non-solid form and subsequently solidified. A method provides an array of such microneedles.