Microneedle is a promising technique for delivering high molecular weight drugs across skin. The microneedles can offer a number of benefits over other drug delivery methods. For example, the drugs only diffuse over a short distance before reaching the blood circulation which enhances the absorption of drugs by the tissue. However, the drug transport behaviour in skin is affected by a complex interplay of many parameters (e.g., microneedle geometries, permeability across skin, etc). In this thesis, many aspects of the microneedle field were examined. A mathematical model for drug transport from microneedle systems into skin was developed. Issues such as microneedle penetration, surface area of the microneedle arrays, etc. were investigated. This work helped us to focus into optimizing the design of microneedles by developing an in-house algorithm to enhance the performance of transdermal drug delivery using microneedles. Following the development of this algorithm, the influence of skin thickness with its classification (i.e., age group, race, etc.) on drug permeability across skin was studied. Attention was then given to determine the effective permeability (Peff) and the effective skin thickness (Heff) for various solid microneedle models. The outcome of this research allowed us to study the influence of microneedle dimensions on the drug concentration in blood (Cb). Furthermore, the 'pattern' (shape) of the microneedles array (i.e., square or rectangular) and the 'distribution' (arrangement) of the microneedles inside an array (i.e., triangular or diamond) were investigated to identify the optimum microneedle models. Finally, the effect of skin metabolism on both the patch (without microneedles) and the microneedle arrays on drug intake were examined.

The objective of this research is the development of an electrically active microneedle array that can deliver biomolecules such as DNA and drugs to epidermal cells by means of electroporation. Properly metallized microneedles could serve as microelectrodes essential for electroporation. Furthermore, the close needle-to-needle spacing of microneedle electrodes provides the advantage of utilizing reduced voltage, which is essential for safety as well as portable applications, while maintaining the large electric fields required for electroporation. Therefore, microneedle arrays can potentially be used as part of a minimally invasive, highly-localized electroporation system for cells in the epidermis layer of the skin. This research consists of three parts: development of the 3-D microfabrication technology to create the microneedle array, fabrication and characterization of the microneedle array, and the electroporation studies performed with the microneedle array. A 3-D fabrication process was developed to produce a microneedle array using an inclined UV exposure technique combined with micromolding technology, potentially enabling low cost mass-manufacture. The developed technology is also capable of fabricating 3-D microstructures of various heights using a single mask. The fabricated microneedle array was then tested to demonstrate its feasibility for through-skin electrical and mechanical functionality using a skin insertion test. It was found that the microneedles were able to penetrate skin without breakage. To study the electrical properties of the array, a finite element simulation was performed to examine the electric field distribution. From these simulation results, a predictive model was constructed to estimate the effective volume for electroporation. Finally, studies to determine hemoglobin release from bovine red blood cells (RBC) and the delivery of molecules such as calcein and bovine serum albumin (BSA) into human prostate cancer cells were used to verify the electrical functionality of this device. This work established that this device can be used to lyse RBC and to deliver molecules, e.g. calcein, into cells, thus supporting our contention that this metallized microneedle array can be used to perform electroporation at reduced voltage. Further studies to show efficacy in skin should now be performed.

Traditional methods of drug delivery to the eye include topical application, intraocular injection and systemic administration; however, each method has its limitation to efficiently delivery drugs to the back of the eye. In this study, microneedles were tested to provide targeted drug delivery into the eye in a minimally invasive way. To better interpret subsequent microneedle studies, we first quantified lateral drug diffusion profile within the sclera, by carrying out a diffusion study of a model compound, sulforhodamine, through human cadaver sclera, and developing a theoretical model for prediction of drug delivery kinetics and distribution. The results showed that measurable amounts of sulforhodamine were detected at distances of 5 and 10 mm from the sulforhodamine donor reservoir at 4 h and 3 days, respectively. The effective lateral diffusivity of sulforhodamine was determined to be 3.82 x 10-6 cm2/s, which is similar in magnitude to the transverse diffusivity. We next assessed the capability of using coated solid metal microneedles to deliver drugs into the ocular tissue in both in vitro and in vivo scenarios. The in vitro insertion tests showed that these microneedles were mechanically strong enough to penetrate into human cadaver sclera, and the coating solution rapidly dissolved off the needles after insertion and had been deposited within the tissue. In the in vivo experiments, microneedle delivery exhibited elevated fluorescein levels in the rabbit eye 60 times greater than that delivered by topical application of the equivalent dose. Similarly, microneedle delivery of pilocarpine caused rapid and extensive pupil constriction. Safety exams reported no inflammatory responses in the eye after microneedle administrations. We also used hollow glass microneedles to infuse solutions into the sclera tissue in vitro and examined the physiological barriers for flow. On average, 18 microliters of sulforhodamine solution and a solution containing nanoparticles was delivered into the sclera upon retraction of the microneedle. Successful delivery of micron-sized particles into the sclera could be improved by breaking down tightly packed collagen and GAG fibers using either collagenase or hyaluronidase.

Transdermal drug delivery system has been limited to small and lipophilic drugs because skin has the intrinsic function to protect the body preventing entry of the external species into the body. In this thesis, two physical methods were studied to overcome the skin barrier in the controlled breakage of the skin barrier and to deliver macromolecules-based drugs through the skin; (1) polysaccharide dissolving microneedles and (2) micro thermal skin ablation. Polysaccharide dissolving microneedles system was designed to break the skin barrier in a minimized size with the mechanically poor material, to release them into skin with the dissolution of microneedles, and to deliver human growth hormone into the living hairless rats. Micro thermal skin ablation was designed to fabricate the device generating the energy impact with the basis of arc discharge, to transfer the energy impact on the skin, to remove stratum corneum selectively with three-dimensionally controlled manner, and to deliver hydrophilic macromolecules through skin.

Currently, biopharmaceuticals including vaccines, proteins, and DNA are delivered almost exclusively through the parenteral route using hypodermic needles. However, injection by hypodermic needles generates pain and causes bleeding. Disposal of these needles also produces biohazardous sharp waste. An alternative delivery tool called microneedles may solve these issues. Microneedles are micron-size needles that deliver drugs or biopharmaceuticals into skin by creating tiny channels in the skin. This thesis focuses on dissolving microneedles in which the needle tips dissolve and release the encapsulated drug or vaccine upon insertion. The project aimed to (i) design and optimize dissolving microneedles for efficient drug and vaccine delivery to the skin, (ii) maintain vaccine stability over long-term storage, and (iii) immunize animals using vaccine encapsulated microneedles. The results showed that influenza vaccine encapsulated in microneedles was more thermally stable than unprocessed vaccine solution over prolonged periods of storage time. In addition, mice immunized with microneedles containing influenza vaccine offered full protection against lethal influenza virus infection. As a result, we envision the newly developed dissolving microneedle system can be a safe, patient compliant, easy to-use and self-administered method for rapid drug and vaccine delivery to the skin.

This thesis describes the fabrication of plastic microneedle devices, their fabrication by injection molding, and analysis of the penetration mechanics. Injection molding is an economical mass-production technique that may encourage widespread adoption of microneedles for drug delivery. Four polymers were injection molded into hexagonal and square patterns of between 91 and 100 needles per array. The patterns and geometries were chosen to study the effect of needle spacing and array design on penetration force. Two needle spacings of approximately 1 mm and 1.5 mm were employed for both patterns. Molded parts showed tip radii below 15 microns, heights of 600 to 750 microns, and an included angle of approximately 30 degrees. An economic analysis performed of the injection molded polymer devices showed that they can be manufactured for approximately $0.10 - $0.179 per part, which should be low enough to gain market acceptance. The added benefits of low pain perception, improved drug delivery for certain treatments, and the possibly of being recyclable make injection molded micro-needle devices a desirable alternative to silicon or metal microneedles. Penetration tests were performed with plastic micro-needle arrays and arrays of steel needles of the same spacings and patterns. Silicone rubber with mechanical properties similar to human skin was used as a skin simulant. The results showed that the micro-needles penetrated skin to depths between 120 and 185 microns depending on pattern, spacing, tip radius and needle length. This depth is sufficient to deliver drug therapies, but not so far that they stimulate the nerve endings present beyond 130 microns inside the dermis layer in human skin. An analytical model was developed to estimate the effects of various microneedle and skin characteristics on penetration force. The model was based on literature sources and derived from test results. The model accounted for coefficient of friction, tip radius, tip angle, and needle spacing, as well as the skin mimic's mechanical properties such as elastic modulus, mode I fracture toughness, and puncture fracture toughness. A Monte Carlo simulation technique was used to correct for errors in needle length and testing angle. Comparison of the experiments to the model showed good agreement.

Naltrexone (NTX) is a drug used primarily in the management of alcohol dependence and opioid dependence. Based on several drawbacks associated with the oral and injectable intramuscular dosage forms of naltrexone currently available on the market, there is substantial interest in delivering naltrexone transdermally. Although naltrexone does not permeate skin at the rate sufficient to reach therapeutic plasma concentrations in humans, novel flux enhancement methods such as microneedles help address this challenge. Earlier work in humans has demonstrated that the use of microneedles achieves plasma concentrations in the lower end of expected therapeutic values. Further flux enhancement is desired to decrease the patch area while increasing drug transport rates. In the present work, several strategies aiming at in vitro flux maximization were employed including: formulation optimization, naltrexone salt screening, and naltrexone prodrug design. While naltrexone prodrugs did not reveal any improved permeation characteristics formulation optimization through decrease in vehicle microviscosity allowed a 5-fold increase in the percutaneous transport rates, and naltrexone glycolate salt selection provided an additional 1.5-fold enhancement in flux. One of the key observations was a good correlation (R2 = 0.99) between vehicle microviscosity and drug transport rates across the microchannel pathway. This finding alone allowed for formulation optimization and, at the same time, provided a potential explanation for the low permeation of high-concentration naltrexone salts and prodrugs. In vivo studies were carried out in Yucatan minipigs using a “poke and patch” microneedle method to deliver NTX•HCl. These studies demonstrated that initial plasma concentrations spiked to 2.5 ng/ml but rapidly dropped to a plateau of below 1 ng/ml. This pharmacokinetic profile could be explained by the use of a mathematical model which identified the importance of microchannel closure kinetics on drug transport. Also, an estimate of diffusional resistance of the viable tissue associated with percutaneous NTX•HCl delivery through microchannels was obtained. Its relatively large value suggests that the effect of diffusional resistance of the dermis in vivo should not be ignored and must be accounted for in order to obtain a good in vitro-in vivo correlation.

Transdermal drug delivery (TDD) is limited by high resistance of the outer layer of the skin, namely stratum corneum which blocks any molecule that is larger than 500 Da. Research on TDD has become very active in recent years and various technologies have been developed to overcome the resistance of the stratum corneum. In particular, researchers have started to consider the possibility of combining the TDD technologies in order to achieve further increment for drug permeability. Microneedles (MNs) and sonophoresis are both promising technologies that can perform notable enhancement in drug permeation via different mechanisms and therefore give a good potential for combining with each other. We discuss the possible ways to achieve this combination as well as how this combination would increase the permeability. Some of the undeveloped (weaker) research areas of MNs and sonophoresis are also discussed in order to understand the true potential of combining the two technologies when they are developed further in the future. We propose several hypothetical combinations based on the possible mechanisms of MNs and sonophoresis.

No description available.

Local anaesthetic drugs are usually administered as symptom relieving drug formulations for the treatment of pain in superficial skin extremities. The anaesthesia is delivered into skin tissues at the site of pain because of nociceptive receptors. Concerns that exist regarding local anaesthetic drug formulations are low drug encapsulation efficiency, polydispersity of colloidal formulations, chemical interactions of released local anaesthetic drug with skin proteins and bulk viscoelastic properties. Complimenting drug formulation characteristics are the desirable rates of controlled release of drug molecules from chosen formulations pertaining to favourable in vitro skin permeation kinetics are imperative pharmaceutics based research areas because skin percutaneous delivery has distinct barrier property restrictions for passive diffusion (PD) of active molecules. Lidocaine is currently the active anaesthetic molecule of choice in local anaesthesia by clinicians because of minimum toxicity and good potency. It is a low molecular weight drug comprising of electron donating and electron withdrawing functional groups with the capacity to interact by hydrogen bonding and electrostatic interactions with several drug formulation vehicles. In this work, a naturally occurring bi-polymeric formulation was achieved with lidocaine NaCMC:gelatine hydrogel. Lidocaine NaCMC:gelatine ratio of 1:2.3 was the most favourable formulation because of faster skin permeation kinetics. Lidocaine NaCMC:gelatine 1:2.7 provided the highest drug encapsulation efficiency. This resulted in high, sustained permeation rates after adaptation of the microneedle (MN) poke and patch technique, past the stratum corneum layer of skin for quick target delivery in attaining a maximum permeation flux of near 6.0 μg/cm2/h in the hypodermis layer. Mass balance of in vitro studies using an indirect approach to quantify lidocaine permeation showed significant lidocaine permeation in skin. Subsequent vertical and horizontal (depth averaged) in vitro studies using similar MN techniques resulted in crossing minimum therapeutic level across a 10 mm radius from the epicentre of the skin sample at major reduced lag times of minutes for vertical permeation and within 0.5 hours for horizontal permeation. Furthermore, the spreadability of lidocaine NaCMC:gelatine hydrogel shows favourability in the control of droplet spreading on MN treated skin.