Now showing 1 - 2 of 2
  • Publication
    Simple and customizable method for fabrication of high-aspect ratio microneedle molds using low-cost 3D printing
    We present a simple and customizable microneedle mold fabrication technique using a low-cost desktop SLA 3D printer. As opposed to conventional microneedle fabrication methods, this technique neither requires complex and expensive manufacturing facilities nor expertise in microfabrication. While most low-cost 3D-printed microneedles to date display low aspect ratios and poor tip sharpness, we show that by introducing a two-step “Print & Fill” mold fabrication method, it is possible to obtain high-aspect ratio sharp needles that are capable of penetrating tissue. Studying first the effect of varying design input parameters and print settings, it is shown that printed needles are always shorter than specified. With decreasing input height, needles also begin displaying an increasingly greater than specified needle base diameter. Both factors contribute to low aspect ratio needles when attempting to print sub-millimeter height needles. By setting input height tall enough, it is possible to print needles with high-aspect ratios and tip radii of 20–40 µm. This tip sharpness is smaller than the specified printer resolution. Consequently, high-aspect ratio sharp needle arrays are printed in basins which are backfilled and cured in a second step, leaving sub-millimeter microneedles exposed resulting microneedle arrays which can be used as male masters. Silicone female master molds are then formed from the fabricated microneedle arrays. Using the molds, both carboxymethyl cellulose loaded with rhodamine B as well as polylactic acid microneedle arrays are produced and their quality examined. A skin insertion study is performed to demonstrate the functional capabilities of arrays made from the fabricated molds. This method can be easily adopted by the microneedle research community for in-house master mold fabrication and parametric optimization of microneedle arrays.
      196Scopus© Citations 94
  • Publication
    Development and Evaluation of 3D-Printed Dry Microneedle Electrodes for Surface Electromyography
    Surface electromyography (sEMG) allows for direct measurement of electrical muscle activity with use in fundamental research and many applications in health and sport. However, conventional surface electrode technology can suffer from poor signal quality, requires careful skin preparation, and is commonly not suited for long-term recording. These drawbacks have challenged translation of sEMG to clinical applications. In this paper, dry 3D-printed microneedle electrodes (MNEs) are proposed to overcome some of the limitations of conventional electrodes. Employing a direct-metal-laser-sintering (DMLS) 3D printing process, a two-step fabrication method is developed to produce sharp medical-grade stainless steel MNEs. The developed MNEs are compared to needle-free versions and to standard wet Ag/AgCl electrodes. Functional testing is conducted to analyze the electrode–skin impedance in healthy human volunteers and sEMG data are recorded from the biceps brachii muscle. Results show that microneedle electrodes display a greatly reduced (≈63%) electrode–skin contact impedance with respect to needle-free electrodes and record sEMG at a signal-to-noise ratio comparable to clinical-grade wet Ag/AgCl electrodes over a period of up to 6 h. Overall, a fabrication method and electrode type are presented which yield high-quality sEMG signals when evaluated in humans, highlighting the potential of MNEs as a platform for biosignal recording.
      91Scopus© Citations 16