Synthesis and characterisation of porous polymer microneedles

Porous Microneedles for Therapy and Diagnosis: Fabrication and Challenges

The use of microneedles (MNs), an innovative transdermal technology, enables efficient, convenient, painless, and controlled-release drug delivery. Porous microneedles (pMNs), special MNs with abundant interconnected pores that can produce capillary action, are gaining increasing attention as a novel MNs technology. pMNs can actively adsorb bioactive ingredients from solutions of drugs or vaccines for in vivo delivery or from interstitial skin fluids (ISFs) for wearable and point-of-care testing (POCT) products. Different pore sizes and porosities of pMNs can be achieved with different materials and preparation processes, which makes the application of pMNs adaptable to multiple scenarios. In addition, easier and faster detection will be accomplished by the smart combination of pMNs with other detection technologies. This paper aims to summarize the recent research progress of pMNs, focusing on the influence of various materials and their corresponding preparation methods on its structure and function display, discussing the key issues and looking forward to the future development.

Hard polymeric porous microneedles on stretchable substrate for transdermal drug delivery

Microneedles offer a convenient transdermal delivery route with potential for long term sustained release of drugs. However current microneedle technologies may not have the mechanical properties for reliable and stable penetration (e.g. hydrogel microneedles). Moreover, it is also challenging to realize microneedle arrays with large size and high flexibility. There is also an inherent upper limit to the amount and kind of drugs that can be loaded in the microneedles. In this paper, we present a new class of polymeric porous microneedles made from biocompatible and photo-curable resin that address these challenges. The microneedles are unique in their ability to load solid drug formulation in concentrated form. We demonstrate the loading and release of solid formulation of anesthetic and non-steroidal anti-inflammatory drugs, namely Lidocaine and Ibuprofen. Paper also demonstrates realization of large area (6 × 20 cm²) flexible and stretchable microneedle patches capable of drug delivery on any body part. Penetration studies were performed in an ex vivo porcine model supplemented through rigorous compression tests to ensure the robustness and rigidity of the microneedles. Detailed release profiles of the microneedle patches were shown in an in vitro skin model. Results show promise for large area transdermal delivery of solid drug formulations using these porous microneedles.

Recent advances in porous microneedles: materials, fabrication, and transdermal applications

In the past two decades, microneedles (MNs), as a painless and simple drug delivery system, have received increasing attention for various biomedical applications such as transdermal drug delivery, interstitial fluid (ISF) extraction, and biosensing. Among the various types of MNs, porous MNs have been recently researched owing to their distinctive and unique characteristics, where porous structures inside MNs with continuous nano- or micro-sized pores can transport drugs or biofluids by capillary action. In addition, a wide range of materials, including non-polymers and polymers, were researched and used to form the porous structures of porous MNs. Adjustable porosity by different fabrication methods enables the achievement of sufficient mechanical strength by optimising fluid flows inside MNs. Moreover, biocompatible porous MNs integrated with biosensors can offer portable detection and rapid measurement of biomarkers in a minimally invasive manner. This review focuses on several aspects of current porous MN technology, including material selection, fabrication processes, biomedical applications, primarily covering transdermal drug delivery, ISF extraction, and biosensing, along with future prospects as well as challenges.

Microfluidic chip connected to porous microneedle array for continuous ISF sampling

Minimally invasive biosensing using microneedles (MNs) is a desirable technology for continuous healthcare monitoring. Among a wide range of MNs, porous MNs are expected to be applied for sampling of interstitial fluids (ISF) by connecting the internal tissue to external measurement devices. In order to realize a continuous measurement of biomarkers in ISF through porous MNs, their integration with a microfluidic chip is a promising approach due to its applicability to micro-total analysis system (μTAS) technology. In this study, we developed a fluidic system to directly interface porous MNs to a microfluidic chip consisting of a capillary pump for the continuous sampling of ISF. The porous and flexible MNs made of PDMS are connected to the microfluidic chip fabricated by standard microelectro-mechanical system (MEMS) processes, showing a continuous flow of phosphate buffered saline (PBS). The developed device will lead to the minimally invasive and continuous biosampling for long-term healthcare monitoring.

Synthesis and characterization of sorbitol laced hydrogel-forming microneedles for therapeutic drug monitoring

The dermal interstitial fluid (ISF) is rich in biomarkers that are of great heuristic value for disease diagnosis and therapeutic drug monitoring. Nevertheless, the current strategies for sampling dermal ISF are both technical and invasive, limiting the potential utility of ISF for clinical medicine and research purposes. In the current work, we present, for the first time, the development, characterization, and evaluation of a novel sorbitol-laced hydrogel-forming microneedles (Sor-Hyd-MN) for sampling dermal ISF. The hydrogel system is fabricated from sorbitol and PEG 10,000 crosslinked with Gantrez® S-97 via esterification in a solvent-free manner. The sorbitol-laced hydrogel rapidly absorbs fluid when placed in aqueous media, reaching a total rise in the mass of 685% relative to the control hydrogel that only reached 436% within 15 mins. When formulated into MNs, the Sor-Hyd-MN exhibited significantly superior (p < 0.001) mechanical properties as evidenced by the minimal MN height reduction (0.9%) relative to the control-MN (3.9%) and Man-Hyd-MN (28.5%) when subjected to a compressive force of 32 N, an analog of patients' thumb pressure. The skin insertion capability of the Sor-Hyd-MN and the control-MN formulation was demonstrated using the in vitro skin simulant, Parafilm® M, and ex vivo neonatal porcine skin. When inserted into ex vivo neonatal porcine skin, the Sor-Hyd-MN showed rapid imbibement of dermal ISF within 15 mins, evidenced via the formation of swollen microchannels, which was 1.2-folds wider than the control formulation. In addition, we also demonstrated for the first time that incorporating sorbitol into Gantrez® S-97 hydrogel-forming MN improved the utility of this formulation in sampling dermal ISF. This was shown from the capability of the Sor-Hyd-MN in extracting the model compounds, isoniazid and theophylline, present within the ISF of ex vivo porcine skin. The Sor-Hyd-MN exhibited an extraction efficiency of 52.4% for isoniazid and 54.4% for theophylline which was significantly higher (p < 0.05) relative to the control formulation in a simple and straightforward manner. This work illustrates that incorporating a hyperosmolyte, such as sorbitol, can further enhance the potential utility of hydrogel-forming MN as a minimally-invasive tool for ISF sampling while providing a potential strategy to extract analytes with ease for subsequent sample analysis.

Polymer microneedles with interconnected porous structures via a phase inversion route for transdermal medical applications

Porous polymer microneedles (MNs) have great potential in transdermal medical applications due to their three-dimensional (3D) porous structures and high porosity. However, existing approaches for the fabrication of such porous polymer MNs are complicated and only applicable to limited types of polymers. Here, we describe a facile yet effective phase inversion route to prepare polymer MNs with highly porous and interconnected pore structures. The fabrication process is simple and mild without involving high temperatures or irradiation, and can be applied to a broad spectrum of commonly used polymers (e.g., cellulose acetate (CA), polysulfone (PSF), polyethersulfone (PES), polylactic acid (PLA), etc.). Thanks to the capillary effect and large cavity given by highly porous and interconnected structures, the resulting porous polymer MNs show the capability of rapidly extracting dermal interstitial fluid (ISF) and efficiently loading/releasing drug compounds. As a proof of concept, we demonstrate the use of these porous CA MNs in the highly efficient extraction of ISF for glucose level detection and administration of insulin for hyperglycemia. Given the recent trend of painless techniques in diagnosis and treatment, the current study provides a new opportunity for the fabrication of MN-based devices for transdermal ISF extraction and drug delivery.

Flexible and porous microneedles of PDMS for continuous glucose monitoring

Microneedle (MN) is a key technology of the biomedical engineering field due to its capability of accessing the biological information in a minimally invasive manner. One of the huge demands for next-generation healthcare monitoring is continuous monitoring, especially of blood glucose concentration. For this, MN should be kept inserted into the human skin for a certain period of time, enduring stresses induced by daily human motion and at the same time measuring biomarkers in ISF. However, conventional MNs for biosensing are not suitable for a long term insertion due to the rigid structure and biological risks of MN breakage. In this study, a novel MN structure is proposed and investigated by combining flexible "sponge-like" porous PDMS matrix and coating by biodissolving hyaluronic acid (HA). The fabricated porous MNs coated with HA show ideal mechanical characteristics, by which the MNs are rigid enough to penetrate the skin and become flexible after insertion into the skin. It is also shown that the MN array successfully extracts ISF in vitro and in vivo not by capillary action but by repeated compressions. The results show the applicability of the flexible MNs to continuous blood glucose monitoring.

Microneedles for transdermal diagnostics: Recent advances and new horizons

Point-of-care testing (POCT), defined as the test performed at or near a patient, has been evolving into a complement to conventional laboratory diagnosis by continually providing portable, cost-effective, and easy-to-use measurement tools. Among them, microneedle-based POCT devices have gained increasing attention from researchers due to the glorious potential for detecting various analytes in a minimally invasive manner. More recently, a novel synergism between microneedle and wearable technologies is expanding their detection capabilities. Herein, we provide an overview on the progress in microneedle-based transdermal biosensors. It covers all the main aspects of the field, including design philosophy, material selection, and working mechanisms as well as the utility of the devices. We also discuss lessons from the past, challenges of the present, and visions for the future on translation of these state-of-the-art technologies from the bench to the bedside.

Functionalized microneedles for continuous glucose monitoring

Microneedles (MNs) have been established as promising medical devices as they are minimally invasive, cause less pain, and can be utilized for self-administration of drugs by patients. There has been rapid development in MNs for transdermal monitoring and diagnostic systems, following the active research on fabrication methods and applications for drug delivery. In this paper, recent investigations on bio-sensing using MNs are reviewed in terms of the applicability to continuous glucose monitoring system (CGMS), which is one of the main research focuses of medical engineering technologies. The trend of the functionalized MNs can be categorized as follows: (i) as a sensing probe, and (ii) as a biological fluid collector. MNs as in vivo sensors are mainly integrated or coated with conductive materials to have the function as electrodes. MNs as fluid collectors are given a certain geometrical design, such as a hollow and porous structure aided by a capillary action or negative pressure, to extract the interstitial fluids or blood for ex vivo analysis. For realization of CGMS with MNs, a long-term accurate measurement by the MN-based sensing probe or a fluidic connection between the MN-based fluid collector and the existing microfluidic measurement systems should be investigated.

Porous polymer coatings on metal microneedles for enhanced drug delivery

We present a simple method to coat microneedles (MNs) uniformly with a porous polymer (PLGA) that can deliver drugs at high rates. Stainless steel (SS) MNs of high mechanical strength were coated with a thin porous polymer layer to enhance their delivery rates. Additionally, to improve the interfacial adhesion between the polymer and MNs, the MN surface was modified by plasma treatment followed by dip coating with polyethyleneimine, a polymer with repeating amine units. The average failure load (the minimum force sufficient for detaching the polymer layer from the surface of SS) recorded for the modified surface coating was 25 N, whereas it was 2.2 N for the non-modified surface. Calcein dye was successfully delivered into porcine skin to a depth of 750 µm by the porous polymer-coated MNs, demonstrating that the developed MNs can pierce skin easily without deformation of MNs; additional skin penetration tests confirmed this finding. For visual comparison, rhodamine B dye was delivered using porous-coated and non-coated MNs in gelatin gel which showed that delivery with porous-coated MNs penetrate deeper when compared with non-coated MNs. Finally, lidocaine and rhodamine B dye were delivered in phosphate-buffered saline (PBS) medium by porous polymer-coated and non-coated MNs. For rhodamine B, drug delivery with the porous-coated MNs was five times higher than that with the non-coated MNs, whereas 25 times more lidocaine was delivered by the porous-coated MNs compared with the non-coated MNs.

An array of porous microneedles for transdermal monitoring of intercellular swelling

An array of porous microneedles was developed for minimally-invasive transdermal electrolytic connection through the human skin barrier, the stratum corneum. The length of microneedle was designed to be 100 μm so that it penetrates into the epidermis layer without pain. Each microneedle was supported by a thicker cylindrical post protruding from a planar substrate to realize its effective penetration even into elastic human skin. Since this support (post and substrate) was equally porous as the needles, the needle chip was entirely permeable for electrolyte. This ion-conductive porous microneedle array was applied to the transdermal conductometry with small direct current for local monitoring of intercellular swelling, edema. The porous needle-based electrode system could be a platform for various transdermal electrical diagnosis and treatments.

Porous polymer microneedles with interconnecting microchannels for rapid fluid transport

We report a porous polymer microneedle array with continuous micropores that has high mechanical strength and water absorption speed.