A multifunctional platform for the rapid prototyping of polymeric microneedle devices
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Full Text E-thesis
Date
2025
Authors
Bocchino, Andrea
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Publisher
University College Cork
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Abstract
Microneedle (MNs) technology has huge appeal for several biomedical applications. The ability to painlessly penetrate the stratum corneum, the uppermost layer of the skin, interfacing with the interstitial fluid (ISF) without drawing any blood, is extremely valuable. Especially when this is coupled with bypassing problems such as rejection of the technology due to needle phobia or need to have trained healthcare personnel for correct application.
MNs can be produced with different materials. Among them, polymer microneedles are becoming more and more predominant due to their low cost and the multitude of different and appealing properties they possess.
However, because of this multitude of properties, many different polymers are used to fabricate MNs. The high variety led to the development of various fabrication processes, which can be difficult to replicate or may require expensive machinery or tools. Moreover, different MN arrays may need additional layers, such as metallization or passivation. Both have little to no dedicated characterization and would further increase the complexity of the manufacturing procedure. Research on polymer MNs can therefore be slow, especially if trying to shift the focus from one application to another. Having a tool able to produce microneedles with different properties using a single process, easily tailorable towards different use cases, would be incredibly valuable to speed up research, potentially bringing new devices to the market.
In this thesis, a platform for the rapid prototyping of polymer MNs is designed, developed and characterised. This platform, based on a core replica moulding process, represents a major advance in the development of a multifunctional process for the laboratory-scale production of microneedles, allowing for easy merging of different polymers and commercially available substrates together with various functionalities, features and customisable properties. This provides a tool that could drastically speed up MN device research and development. To my knowledge, this is the first platform which enables the merging of several degradable, swellable, and medical polymers with fabric, flexible substrates, and metals. Different metallization and passivation techniques are analysed and compared, providing insights on what is preferrable to use in different applications and how to more efficiently implement it. In fact, although both procedures are commonly used on MN arrays, there is a scarcity of proper characterization tailored specifically towards their implementation on MN devices. The value and usability of the platform has then been demonstrated by several examples focussing on drug delivery, biopotential capturing, and continuous biomarkers monitoring.
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Keywords
Microneedles , Sensors , Wearable devices , Electrodes , Moulding , Polymers , Drug delivery , Platform
Citation
Bocchino, A. 2025. A multifunctional platform for the rapid prototyping of polymeric microneedle devices. PhD Thesis, University College Cork.