Microneedle Assembly Additive Manufacturing with Multi-Nozzle Extrusion
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Solution Overview
Problem
Current three-dimensional printing technologies face limitations in producing microneedle arrays pre-loaded with drugs without human operator participation, and existing methods for drug delivery, such as hypodermic needles, are cumbersome and require clinical administration.
Innovation Solution
An additive manufacturing apparatus comprising a conveyor, extruders, printhead modules, and a controller that forms support layers with microneedle protrusions and applies medicaments to these protrusions, enabling the production of microneedle assemblies with drugs for transdermal delivery without operator intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single nozzle extruder is used to emit build material, then the device complexity is reduced, but the productivity decreases due to considerable time required to form three-dimensional printed objects
Solution Approach 1:
The extruder is divided into multiple independent nozzles (first nozzle, second nozzle, third nozzle) that can operate simultaneously to deposit different materials (biocompatible material, drug solution, protective coating) or the same material in different locations, thereby increasing productivity without significantly increasing overall device complexity
Solution Approach 2:
The multi-nozzle extruder system is designed to perform multiple functions: forming microneedle structures, delivering drugs, and applying protective coatings, all through a single integrated extruder unit with multiple nozzles, reducing the need for separate processing equipment
2Manufacturing precision
If nozzles with narrower diameters are used to form finer detailed structures, then the manufacturing precision is improved, but the productivity decreases due to increased time required to build three-dimensional objects
Solution Approach 1:
The extruder incorporates nozzles of different diameters (first nozzle with first diameter, second nozzle with second diameter, third nozzle with third diameter) that can be selectively activated based on the required feature size, allowing fine details to be formed with narrow nozzles while broader areas are filled by wider nozzles, thus maintaining both precision and productivity
Solution Approach 2:
The system adds the dimension of nozzle diameter selection to the traditional single-nozzle operation, enabling the extruder to adapt its effective deposition width dynamically by selecting appropriate nozzles for different regions of the microneedle array, resolving the trade-off between detail precision and overall formation speed
3Ease of operation
If multiple stations and human operator participation are used in microneedle array manufacturing, then the ease of operation is maintained for complex tasks, but the extent of automation decreases
Solution Approach 1:
Multiple manufacturing functions (microneedle formation, drug loading, protective coating application) that traditionally required separate stations and manual operations are merged into a single automated extrusion process where the multi-nozzle extruder performs all tasks in sequence, achieving high automation while simplifying the overall manufacturing workflow
Solution Approach 2:
The system pre-loads the extruder with multiple materials (biocompatible material for microneedle structure, drug solution for medicament loading, protective coating material) and uses automated control to sequence their deposition, eliminating the need for manual material changes and operator intervention during the manufacturing process
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 automated production of microneedle assemblies pre-loaded with drugs, enhancing drug delivery efficiency and reducing the need for clinical administration, while improving precision and speed in forming detailed structures.
Implementation Method 1
Some of these technologies use extruders that soften or melt extrusion material, such as ABS plastic, into thermoplastic material
Implementation Method 2
Each inkjet has a thermal or piezoelectric actuator that is coupled to a printhead controller. The actuators in the printheads respond to the firing signals by ejecting ink drops
Implementation Method 3
Each inkjet has a thermal or piezoelectric actuator that is coupled to a printhead controller
Implementation Method 4
After each layer of the three-dimensional printed object is formed, the thermoplastic material cools and hardens to bond the layer to an underlying layer
Data Source
AI summary
An additive manufacturing system has an extruder and a printhead module with a conveyor for moving between the extruder and the printhead module. The extruder is operated to form a support layer having microneedle protrusions. The conveyor moves the support layer having the microneedle protrusions to a position opposite the printhead module for sharpening of the microneedle protrusions and the application of a medicament to the sharpened microneedle protrusions.