Polymer particle-based micromolding to fabricate novel microstructures

Abstract

Conventional micromolding provides rapid and low-cost methods to fabricate polymer microstructures, but has limitations when producing sophisticated designs. To provide more versatile micromolding techniques, we developed methods based on filling micromolds with polymer microparticles, as opposed to polymer melts, to produce microstructures composed of multiple materials, having complex geometries, and made using mild processing conditions. Polymer microparticles of 1 to 30 µm in size were made from PLA, PGA and PLGA using established spray drying and emulsion techniques either with or without encapsulating model drug compounds. These polymer microparticles were filled into PDMS micromolds at room temperature and melted or bonded together to form microstructures according to different protocols. Porous microstructures were fabricated by ultrasonically welding microparticles together in the mold while maintaining the voids inherent in their packing structure. Multi-layered microstructures were fabricated to have different compositions of polymers and encapsulated compounds located in different regions of the microstructures. More complex arrowhead microstructures were fabricated in a two-step process using a single mold. To assess possible applications, microstructures were designed as microneedles for minimally invasive drug delivery. Multilayer microneedles were shown to insert into cadaver tissue and, according to design, detach from their base substrate and remain embedded in the tissue for controlled release drug delivery over time. We conclude that polymer particlebased micromolding can encapsulate compounds within microstructures composed of multiple materials, having complex geometries, and made using mild processing conditions.

Porous Inorganic Drug Delivery Systems—a Review

“…This approach is valuable for applications requiring large surface areas, such as the insertion of microneedles into the skin to serve as tissue engineering scaffolds or biosensors. Microneedles may disengage from their substrate and remain embedded in the tissue for controlled drug delivery (71). Utilising microneedles from biodegradable polymers (e.g.…”

Induction of broad immunity by thermostabilised vaccines incorporated in dissolvable microneedles using novel fabrication methods

“…proposed [4][5][6][7][8]. Most of these methods rely on filling a liquid formulation into a mould, having microdepressions or pores that define the final structure and composition of the microneedles, and subsequent drying and/or hardening of the material (Fig.…”

Criterion for Constitutional Supercooling at Solid-Liquid Interface in Initial Transient Solidification with Varying Solute Content at Interface

“…In the casting field, also, there have been many reports [1][2][3][4][5] on micro-casting techniques and production of micro-mold, but there are no reports on formation mechanisms of the solidification structure. In the solidification of micro-scale components, the steady state solidification is very limited or does not exist, but the initial and terminal transient solidifications are dominant.…”