Parametric optimization of two-photon direct laser writing process for manufacturing polymeric microneedles

Article

Faraji Rad, Zahra, Prewett, Philip D. and Davies, Graham J.. 2022. "Parametric optimization of two-photon direct laser writing process for manufacturing polymeric microneedles." Additive Manufacturing. 56, pp. 1-14. https://doi.org/10.1016/j.addma.2022.102953
Article Title

Parametric optimization of two-photon direct laser writing process for manufacturing polymeric microneedles

ERA Journal ID210040
Article CategoryArticle
AuthorsFaraji Rad, Zahra (Author), Prewett, Philip D. (Author) and Davies, Graham J. (Author)
Journal TitleAdditive Manufacturing
Journal Citation56, pp. 1-14
Article Number102953
Number of Pages14
Year2022
PublisherElsevier
Place of PublicationNetherlands
ISSN2214-7810
2214-8604
Digital Object Identifier (DOI)https://doi.org/10.1016/j.addma.2022.102953
Web Address (URL)https://www.sciencedirect.com/science/article/pii/S2214860422003475
Abstract

Laser-based additive manufacturing methods have been rapidly developed in recent years and it is anticipated that this new generation of microfabrication tools will dominate the market in the near future. Three-dimensional (3D) microprinting based on two-photon polymerization allows manufacturing of complex microstructures with a resolution down to hundreds of nanometers. In recent years, the technology has been used for the manufacturing of a variety of nano- and micro-sized features such as microfluidic devices, photonics, micro-optics, and microneedle arrays. Microneedles have been mainly studied for transdermal drug delivery of therapeutic agents across the skin and withdrawing bio samples for point-of-care (POC) diagnostics. With significant development being made, it is now possible to 3D print complex microneedle structures directly from computer-aided design (CAD) models by the two-photon direct laser writing technique. However, selecting the optimal parameters and investigating the possible arrangement for the print process often involves intensive optimization process and testing. Herein we report on fabrication of highly detailed microneedles using the two-photon direct laser writing process with a discussion of optimization and parameter selection for microprinting tall microneedles with side-channels and other complex designs. Due to the long printing time, this manufacturing process is currently best suited to print master microneedles. Therefore, we further demonstrate the replication capabilities of the master microneedles by the soft embossing process. Additionally, the mechanical characteristics and insertion force of the microneedle replicas are investigated.

Keywords3D laser lithography; 3D printing; Drug delivery; Microneedles; Point-of-care diagnostics; Two-photon polymerization
ANZSRC Field of Research 2020400308. Medical devices
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Byline AffiliationsSchool of Engineering
University of Birmingham, United Kingdom
University of New South Wales
Institution of OriginUniversity of Southern Queensland
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