High-fidelity replication of thermoplastic microneedles with open microfluidic channels

Article

Faraji Rad, Zahra, Nordon, Robert E., Anthony, Carl J., Bilston, Lynne, Prewett, Philip D., Arns, Ji-Youn, Arns, Christoph H., Zhang, Liangchi and Davies, Graham J.. 2017. "High-fidelity replication of thermoplastic microneedles with open microfluidic channels." Microsystems and Nanoengineering. 3, pp. 1-11. https://doi.org/10.1038/micronano.2017.34
Article Title

High-fidelity replication of thermoplastic microneedles with open microfluidic channels

ERA Journal ID213691
Article CategoryArticle
AuthorsFaraji Rad, Zahra (Author), Nordon, Robert E. (Author), Anthony, Carl J. (Author), Bilston, Lynne (Author), Prewett, Philip D. (Author), Arns, Ji-Youn (Author), Arns, Christoph H. (Author), Zhang, Liangchi (Author) and Davies, Graham J. (Author)
Journal TitleMicrosystems and Nanoengineering
Journal Citation3, pp. 1-11
Article Number17034
Number of Pages11
Year2017
PublisherNature Publishing Group
Place of PublicationUnited Kingdom
ISSN2055-7434
2096-1030
Digital Object Identifier (DOI)https://doi.org/10.1038/micronano.2017.34
Web Address (URL)https://www.nature.com/articles/micronano201734
Abstract

Development of microneedles for unskilled and painless collection of blood or drug delivery addresses the quality of healthcare through early intervention at point-of-care. Microneedles with submicron to millimeter features have been fabricated from materials such as metals, silicon, and polymers by subtractive machining or etching. However, to date, large-scale manufacture of hollow microneedles has been limited by the cost and complexity of microfabrication techniques. This paper reports a novel manufacturing method that may overcome the complexity of hollow microneedle fabrication. Prototype microneedles with open microfluidic channels are fabricated by laser stereolithography. Thermoplastic replicas are manufactured from these templates by soft-embossing with high fidelity at submicron resolution. The manufacturing advantages are (a) direct printing from computer-aided design (CAD) drawing without the constraints imposed by subtractive machining or etching processes, (b) high-fidelity replication of prototype geometries with multiple reuses of elastomeric molds, (c) shorter manufacturing time compared to three-dimensional stereolithography, and (d) integration of microneedles with open-channel microfluidics. Future work will address development of open-channel microfluidics for drug delivery, fluid sampling and analysis.

KeywordsDrug delivery; Laser lithography; Microneedles; Point-of-care diagnostics; Soft embossing
ANZSRC Field of Research 2020401609. Polymers and plastics
400303. Biomechanical engineering
400302. Biomaterials
Byline AffiliationsUniversity of New South Wales
University of Birmingham, United Kingdom
Institution of OriginUniversity of Southern Queensland
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