Integrated Lithographic Molding for Microneedle-Based Devices

This paper presents a new fabrication method consisting of lithographically defining multiple layers of high aspect-ratio photoresist onto preprocessed silicon substrates and release of the polymer by the lost mold or sacrificial layer technique, coined by us as lithographic molding. The process methodology was demonstrated fabricating out-of-plane polymeric hollow microneedles. First, the fabrication of needle tips was demonstrated for polymeric microneedles with an outer diameter of 250 mum, through-hole capillaries of 75-mum diameter and a needle shaft length of 430 mum by lithographic processing of SU-8 onto simple v-grooves. Second, the technique was extended to gain more freedom in tip shape design, needle shaft length and use of filling materials. A novel combination of silicon dry and wet etching is introduced that allows highly accurate and repetitive lithographic molding of a complex shape. Both techniques consent to the lithographic integration of microfluidic back plates forming a patch-type device. These microneedle-integrated patches offer a feasible solution for medical applications that demand an easy to use point-of-care sample collector, for example, in blood diagnostics for lithium therapy. Although microchip capillary electrophoresis glass devices were addressed earlier, here, we show for the first time the complete diagnostic method based on microneedles made from SU-8

Pharma-engineering of multifunctional microneedle array device for application in chronic pain

Chronic pain poses a major concern to modern medicine and is frequently undertreated, causing suffering and disability. Transdermal delivery is the pivot to which analgesic research in drug delivery has centralized especially with the confines of needle phobias and associated pain related to traditional injections, and the existing limitations associated with oral drug delivery. Highlighted within this thesis is the possibility of further developing transdermal drug delivery for chronic pain treatment using an Electro-Modulated Hydrogel- Microneedle array (EMHM) prototype device for the delivery of analgesic medicatio

Towards rapid 3D direct manufacture of biomechanical microstructures

The field of stereolithography has developed rapidly over the last 20 years, and commercially available systems currently have sufficient resolution for use in microengineering applications. However, they have not as yet been fully exploited in this field. This thesis investigates the possible microengineering applications of microstereolithography systems, specifically in the areas of active microfluidic devices and microneedles. The fields of micropumps and microvalves, stereolithography and microneedles are reviewed, and a variety of test builds were fabricated using the EnvisionTEC Perfactory Mini Multi-Lens stereolithography system in order to define its capabilities. A number of microneedle geometries were considered. This number was narrowed down using finite element modelling, before another simulation was used to optimise these structures. 9 × 9 arrays of 400 μm tall, 300 μm base diameter microneedles were subjected to mechanical testing. Per needle failure forces of 0.263 and 0.243 N were recorded for the selected geometries, stepped cone and inverted trumpet. The 90 μm needle tips were subjected to between 30 and 32 MPa of pressure at their failure point - more than 10 times the required pressure to puncture average human skin. A range of monolithic micropumps were produced with integrated 4 mm diameter single-layer 70 μm-thick membranes used as the basis for a reciprocating displacement operating principle. The membranes were tested using an oscillating pneumatic actuation, and were found reliable (>1,000,000 cycles) up to 2.0 PSIG. Pneumatic single-membrane nozzle/diffuser rectified devices produced flow rates of up to 1,000 μl/min with backpressures of up to 375 Pa. Another device rectified using active membrane valves was found to self-prime, and produced backpressures of up to 4.9 kPa. These devices and structures show great promise for inclusion in complex, fully integrated and active microfluidic systems fabricated using microstereolithography alone, with implications for both cost of manufacture and lead time

Novel approaches to engineer glucose biosensors

This thesis was submitted for the degree of Doctor of Philosophy and awarded by Brunel University.Designing a biosensor capable of continuously monitoring blood glucose concentration in people with diabetes has been a major challenge for over three decades. In this work we attempt to develop a novel microspike based minimally invasive biosensor for this purpose. Also, as a part of an ongoing study, we attempt to improve the current design of coil-type implantable biosensors. Microspikes, which are able to painlessly penetrate the skin layer, were fabricated using lithographic techniques and sputtered with gold to serve as an electrode. The biosensor design is based on thiomalic acid self-assembled monolayer (SAM) on which glucose oxidase was immobilised by a simple coupling technique together with a tetrathiafulvalene mediator entrapped in an epoxy-polyurethane permselective membrane. Functional testing revealed that such modified sensors are capable of detecting glucose concentration within the clinically relevant range. This was followed by studying the microspike based biosensors incorporated into the microfluidics platform mimicking the sensor behaviour in interstitial fluid. Data from these experiments revealed that the sensor response is mainly dependent on enzyme kinetics rather than membrane permeability to glucose. In contrast, an attempt to address the reproducibility issues of coil-type biosensors is presented. The hypothesis for this study was that a crosslinked hydrogel would have a sufficiently uniform porosity and hydrophilicity to address the variability in sensor sensitivity. The hydrogel was prepared by crosslinking di-hydroxyethyl methacrylate, hydroxyethyl methacrylate and N-vinyl pyrrolidone with 2.5 mol% ethylene glycol dimethacrylate using the water soluble initiators – ammonium persulphate and sodium metabisulfite under a nitrogen atmosphere. The hydrogel was applied to the sensor by dip coating during polymerisation. Electrochemical measurements revealed that the response characteristics of sensors coated with this membrane are highly consistent. Scanning Electrochemical Microscopy (SECM) was used to spatially resolve glucose diffusion through the membrane by measuring the consequent hydrogen peroxide release and compared with an epoxy- polyurethane membrane

DEVELOPMENT OF MICRONEEDLES ON FLEXIBLE SKIN PATCH WITH FUNCTIONAL COMPONENTS FOR TRANSDERMAL DRUG DELIVERY APPLICATIONS

Ph.DDOCTOR OF PHILOSOPH

Towards rapid 3D direct manufacture of biomechanical microstructures

The field of stereolithography has developed rapidly over the last 20 years, and commercially available systems currently have sufficient resolution for use in microengineering applications. However, they have not as yet been fully exploited in this field. This thesis investigates the possible microengineering applications of microstereolithography systems, specifically in the areas of active microfluidic devices and microneedles. The fields of micropumps and microvalves, stereolithography and microneedles are reviewed, and a variety of test builds were fabricated using the EnvisionTEC Perfactory Mini Multi-Lens stereolithography system in order to define its capabilities. A number of microneedle geometries were considered. This number was narrowed down using finite element modelling, before another simulation was used to optimise these structures. 9 × 9 arrays of 400 μm tall, 300 μm base diameter microneedles were subjected to mechanical testing. Per needle failure forces of 0.263 and 0.243 N were recorded for the selected geometries, stepped cone and inverted trumpet. The 90 μm needle tips were subjected to between 30 and 32 MPa of pressure at their failure point - more than 10 times the required pressure to puncture average human skin. A range of monolithic micropumps were produced with integrated 4 mm diameter single-layer 70 μm-thick membranes used as the basis for a reciprocating displacement operating principle. The membranes were tested using an oscillating pneumatic actuation, and were found reliable (>1,000,000 cycles) up to 2.0 PSIG. Pneumatic single-membrane nozzle/diffuser rectified devices produced flow rates of up to 1,000 μl/min with backpressures of up to 375 Pa. Another device rectified using active membrane valves was found to self-prime, and produced backpressures of up to 4.9 kPa. These devices and structures show great promise for inclusion in complex, fully integrated and active microfluidic systems fabricated using microstereolithography alone, with implications for both cost of manufacture and lead time.EThOS - Electronic Theses Online ServiceEngineering and Physical Sciences Research Council (EPSRC)GBUnited Kingdo

Suportes físicos para imobilização de sistemas de libertação controlada de fármacos bioinspirados pelo processo de polinização

Mestrado em Biotecnologia Industrial e AmbientalNos últimos anos, a administração transdérmica de fármacos foi aponte como uma via de libertação de fármacos de sucesso devido às suas enumeras vantagens. Relativamente aos sistemas convencionais, este é um sistema não doloroso, apresenta menos efeitos secundários e possibilita uma dose menos frequente. Os pensos representam a maior quota do mercado de sistemas de libertação transdérmica de fármaco. No entanto, a sua aplicação tem sido restringida pelos atuais problemas associados à sua administração passiva. Com base no conceito de biomimetismo, um novo e otimizado sistema para administração transdérmica de fármacos é aqui proposto, bioinspirado na capacidade das abelhas aprisionarem e, consequentemente, libertarem o pólen durante o processo de polinização. Assim, foi desenhado um penso hierárico biomimético obtido a partir de polidimetilsiloxano (PDMS) com um micropadrão de pilares (imitando o pêlo presente nas patas das abelhas). A otimização do sistema foi obtida pela conjugação de micropilares espaçados com a mesma distância que o diâmetro das partículas de fármaco. Obteve-se assim uma eficiência de aprisionamento de 24,8 ± 0,4 mg/cm2, estando acima dos valores obtidos para os pensos atualmente disponíveis no mercado, bem como na maioria dos trabalhos até aqui efetuados. A tetraciclina, um antibiótico modelo, foi aqui utilizado para determinar o perfil de libertação de dois sistemas diferentes: pensos com tetraciclina em pó ou com micropartículas de alginato encapsuladas com esse mesmo fármaco. Enquanto o pó de tetraciclina foi rapidamente libertado, o sistema mais complexo permitiu uma libertação controlada do composto ativo durante 5 dias. Os pensos foram caracterizados por microscopia eletrónica de varrimento, microscopia de fluorescência e resistência à tração. Além disso, a atividade antimicrobiana também foi também verificada. Em suma, os resultados obtidos propõem a aplicação deste penso a nível clínico, proporcionando uma elevada concentração de fármaco que poderá resolver os problemas atuais associados aos sistemas de administração passiva de fármacos.In the last years, transdermal drug delivery has been exploited as a successful controlled drug release route due their several advantages (e.g. no painful, less frequent dosage and side effects), being the patches the largest market share of such systems. Nevertheless, current problems associated with passive delivery patches have been limiting their application. Based on the insights behind the biomimetics concept, herein we propose as novel and optimized system for transdermal drug delivery purposes, a bioinspired patch based on the remarkable bee’s ability to catch and release the pollen during pollination. For this purpose, a hierarchical biomimetic polydimethylsiloxane (PDMS) micropatterning patch with micropillars (mimicking the hair of bee’s legs) was engineered. An optimized system was obtained through the combination of patch with micropillars spaced with the same distance as drug microparticles' diameter. In fact, an entrapment efficiency of 24.8 ± 0.4 mg/cm2 was achieved, being above the actual commercially available patches and most of the current research works. The release profile was determinate to two different systems: patches with either tetracycline hydrochloride powder or tetracycline loaded alginate microparticles, a model antibiotic. While tetracycline powder was immediately release, the most complex system allowed for a controlled and sustained release of the active pharmaceutical ingredient (API) for 5 days. The engineered patches were characterized by SEM, fluorescent microscopy, tensile strength and antimicrobial activity was also verified. The results herein obtained suggest that the optimized patch could be further developed for clinical applications, providing high drug concentration that could solve the current problems associated with passive drug delivery patches

Biomicrofluidics: recent trends and future challenges

Biomicrofluidics is an active area of research at present, exploring the synergy of microfluidics with cellular and molecular biology, biotechnology, and biomedical engineering. The present article outlines the recent advancements in these areas, including the development of novel lab-on-a-chip based applications. Particular emphasis is given on the microfluidics-based handling of DNA, cells, and proteins, as well as fundamental microfluidic considerations for design of biomedical microdevices. Future directions of research on these topics are also discussed

Novel approaches to engineer glucose biosensors

Designing a biosensor capable of continuously monitoring blood glucose concentration in people with diabetes has been a major challenge for over three decades. In this work we attempt to develop a novel microspike based minimally invasive biosensor for this purpose. Also, as a part of an ongoing study, we attempt to improve the current design of coil-type implantable biosensors. Microspikes, which are able to painlessly penetrate the skin layer, were fabricated using lithographic techniques and sputtered with gold to serve as an electrode. The biosensor design is based on thiomalic acid self-assembled monolayer (SAM) on which glucose oxidase was immobilised by a simple coupling technique together with a tetrathiafulvalene mediator entrapped in an epoxy-polyurethane permselective membrane. Functional testing revealed that such modified sensors are capable of detecting glucose concentration within the clinically relevant range. This was followed by studying the microspike based biosensors incorporated into the microfluidics platform mimicking the sensor behaviour in interstitial fluid. Data from these experiments revealed that the sensor response is mainly dependent on enzyme kinetics rather than membrane permeability to glucose. In contrast, an attempt to address the reproducibility issues of coil-type biosensors is presented. The hypothesis for this study was that a crosslinked hydrogel would have a sufficiently uniform porosity and hydrophilicity to address the variability in sensor sensitivity. The hydrogel was prepared by crosslinking di-hydroxyethyl methacrylate, hydroxyethyl methacrylate and N-vinyl pyrrolidone with 2.5 mol% ethylene glycol dimethacrylate using the water soluble initiators – ammonium persulphate and sodium metabisulfite under a nitrogen atmosphere. The hydrogel was applied to the sensor by dip coating during polymerisation. Electrochemical measurements revealed that the response characteristics of sensors coated with this membrane are highly consistent. Scanning Electrochemical Microscopy (SECM) was used to spatially resolve glucose diffusion through the membrane by measuring the consequent hydrogen peroxide release and compared with an epoxy- polyurethane membrane.EThOS - Electronic Theses Online ServiceGBUnited Kingdo