Permeable Template Casting for Complete Microneedle Filling
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Solution Overview
Problem
Existing methods for manufacturing microneedles are inadequate in quality and quantity due to issues such as incomplete filling of casting molds, air inclusions, and hydrophobic characteristics leading to defective microneedles.
Innovation Solution
A device and method utilizing a permeable template with a vacuum-generating system to ensure complete filling of microstructures by preventing gas inclusions, using materials like ceramic, metal, and polymer, and employing a vacuum chamber to maintain negative pressure during the casting process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a casting mold is used to manufacture microneedles, then microneedles can be produced in batches, but air inclusions and incomplete filling occur due to hydrophobic characteristics
Solution Approach 1:
The patent employs a permeable template with porous structure that allows gas to pass through during the casting process. The template's permeability enables air inclusions to be evacuated while maintaining the structural integrity needed for precise microneedle formation, thus resolving the contradiction between batch production capability and filling completeness.
Solution Approach 2:
The patent creates a vacuum environment during the casting process to remove air inclusions from the mold cavity. By establishing a negative pressure environment, the system prevents air pockets from forming and ensures complete filling of the mold with casting material, thereby improving manufacturing precision while maintaining batch production capability.
2Productivity
If a casting mold is used to manufacture microneedles, then microneedles can be produced in batches, but defective microneedles are produced due to air inclusions
Solution Approach 1:
The permeable template with controlled porosity allows gas to escape during casting while maintaining structural fidelity. This ensures that microneedles produced in batch are free from air inclusion defects, thereby improving reliability without sacrificing productivity.
Solution Approach 2:
By applying vacuum during the casting process, the system creates an environment that prevents air inclusion formation. This ensures high reliability of the produced microneedles while maintaining the ability to produce them in batches, thus resolving the contradiction between productivity and reliability.
3Manufacturing precision
If a permeable template with vacuum is used, then air inclusions are eliminated, but the device complexity increases
Solution Approach 1:
The permeable template integrates the gas evacuation function directly into the mold structure itself. This eliminates the need for complex external gas removal systems, as the porous template passively allows air to escape during casting, thereby reducing device complexity while maintaining filling completeness.
Solution Approach 2:
The permeable template performs the gas evacuation function autonomously through its inherent porosity during the casting process. The template self-regulates the gas removal without requiring active control systems or complex vacuum equipment, thus reducing device complexity while ensuring complete filling.
4Manufacturing precision
If a permeable template with vacuum is used, then air inclusions are eliminated, but the loss of time increases due to vacuum generation and maintenance
Solution Approach 1:
The permeable template enables passive, continuous gas evacuation throughout the casting process without requiring time-consuming vacuum generation and maintenance phases. Gas is removed automatically as the material fills the mold, eliminating the need for separate vacuum treatment steps and reducing overall process time while maintaining filling completeness.
Solution Approach 2:
The template's inherent porosity allows it to perform gas evacuation continuously and passively during casting, without requiring active vacuum systems that would extend process time. This self-service mechanism eliminates air inclusions in real-time during filling, reducing the total manufacturing time while ensuring complete filling.
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
The solution ensures defect-free microneedle production by eliminating air inclusions, thereby improving the manufacturing process and ensuring accurate administration of active agents.
Implementation Method 1
the template is permeable, in particular gas permeable or gas transmissible. A liquid casting material fed onto the template cannot pass through the template, for example, but gases, such as air inclusions, can pass through the template
Implementation Method 2
A device (10) for manufacturing microstructures comprises a vacuum-generating device (16) connected to the template (12). The connection of the vacuum-generating device (16) to the template (12) is configured such that a vacuum is applied in particularly directly to at least one side of the template (12)
Implementation Method 3
employing a vacuum chamber to maintain negative pressure during the casting process
Data Source
AI summary
A device for manufacturing microstructures including a permeable template, wherein the template comprises at least one recess for manufacturing the microstructures. In addition, the device comprises a vacuum-generating device connected to the template such that a vacuum is applied to at least one side of the template. Further, a method for filling a permeable template, wherein the template comprises at least one recess for manufacturing microstructures. The method comprises feeding the at least one substance to be filled in to the template as well as generating a vacuum on at least one side of the template