Braided Wire Microneedles for Strong, Precise Device Implantation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The development of micro-scale surgical instruments that are strong, easy to use, and reliable is hindered by the limitations of existing fabrication methods, which struggle to produce instruments with optimal properties for precision and biocompatibility.
Innovation Solution
The method involves fabricating microneedles by winding multiple lengths of wire together, brazing them to create a strong structure, and incorporating a reversible engagement feature to facilitate the implantation of devices into biological tissues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If microneedles are made from single wire structures, then fabrication is simple, but strength and reliability are insufficient
Solution Approach 1:
The microneedle is constructed from multiple discrete wire segments (typically 3-7 segments) rather than a single continuous wire. Each segment is individually positioned and then joined through brazing, creating a segmented structure that distributes mechanical stress and enhances overall strength while maintaining fabricability through standardized segment preparation and assembly procedures
Solution Approach 2:
Multiple wire segments are merged into a single integrated microneedle structure through brazing. The individual wire segments are positioned in parallel and joined at their endpoints using brazing material, creating a unified structure that combines the strength of multiple wires while maintaining the thin profile necessary for minimally invasive insertion
2Manufacturing precision
If microneedles are made thinner for precision insertion, then insertion accuracy improves, but structural integrity deteriorates
Solution Approach 1:
The microneedle is divided into multiple thin wire segments (typically 3-7 segments) rather than using a single thin wire. This segmentation allows each individual segment to remain thin enough for precise insertion while the collective arrangement of multiple segments provides enhanced structural integrity and resistance to bending or breakage during insertion and implantation
Solution Approach 2:
The microneedle employs a composite structure consisting of multiple wire segments joined by brazing material. This composite construction combines the flexibility and thinness of individual wire segments with the strength provided by the brazed joints, creating a structure that is both insertion-friendly and mechanically robust
3Reliability
If traditional fabrication methods are used, then manufacturing process is simple, but biocompatibility and reliability are compromised
Solution Approach 1:
The fabrication process incorporates controlled parameter changes including precise temperature control during brazing, specific atmospheric conditions (inert or vacuum environment), and controlled cooling rates. These parameter changes ensure proper metallurgical bonding between wire segments and brazing material while maintaining biocompatibility of the final structure
Solution Approach 2:
The brazing process is performed in an inert atmosphere (such as argon or nitrogen) or vacuum environment to prevent oxidation of the wire and brazing material. This controlled environment ensures clean, reliable joints without oxide contamination, enhancing both the reliability and biocompatibility of the microneedle while maintaining fabrication feasibility through standard vacuum or inert gas handling procedures
4Strength
If microneedles require complex assembly for strength, then strength improves, but ease of use deteriorates
Solution Approach 1:
The wire segments are pre-positioned and pre-aligned in their final configuration before brazing. This preliminary arrangement ensures that the complex multi-segment assembly is performed in a controlled, systematic manner rather than requiring complex manipulation during use. The segments are temporarily held in position during brazing, and once joined, the structure is stable and ready for insertion without requiring further assembly steps
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 approach enables the creation of microneedles that are strong, biocompatible, and easy to use, allowing for precise insertion and implantation of devices into biological tissues with minimal trauma and high accuracy.
Implementation Method 1
Microneedles fabricated according to the herein described methods will generally be constructed of multiple lengths of wire winded together, brazed and further manipulated
Implementation Method 2
The subject methods may include ablating a section of the outer membrane and inserting the implantable device through the ablated section of outer membrane
Data Source
AI summary
Methods are provided for the fabrication of microneedles. Microneedles fabricated according to the herein described methods will generally be constructed of multiple lengths of wire winded together, brazed and further manipulated to include a reversible engagement feature. The subject microneedles may find use in a variety of applications and, among other purposes, the reversible engagement feature of such a microneedle may by employed in implanting an implantable device into a biological tissue. Also provided are methods of inserting an implantable device into a biological tissue having an outer membrane. The subject methods may include ablating a section of the outer membrane and inserting the implantable device through the ablated section of outer membrane, including e.g., where the implantable device is inserted using a microneedle including e.g., those microneedles for which methods of fabrication are provided herein.