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Microinjection protocols that involve using a hollow, high-aspect-ratio microneedle to deliver foreign material (e.g., cells, DNA, viruses, and micro/nanoparticles) into biological targets (e.g., embryos, tissues, and organisms) are essential to diverse biomedical applications in both research and clinical settings. A key deficit of such protocols, however, is that standard microneedle architectures are inherently susceptible to clogging-induced failure modes, which can diminish experimental rigor and lead to failed microinjections. Additive manufacturing (or “three-dimensional (3D) printing”) strategies based on “Two-Photon Direct Laser Writing (DLW)” offer a promising route to address clogging failure phenomena by rearchitecting the needle tip, yet achieving 3D-printed microneedles with the mechanical strength necessary to penetrate into biological targets (e.g., embryos) has remained a critical barrier to efficacy. To overcome this barrier, here we harness a recently reported polyhedral oligomeric silsequioxane (POSS) photomaterial to DLW-print fused silica glass high-aspect-ratio microinjection needles with enhanced mechanical strength. Experimental results for POSS-based 3D-nanoprinted microneedles with inner and outer diameters of 10 μm and 15 μm, respectively, and heights ranging from 500–750 μm revealed that the needles not only enabled successful puncture and penetration into early-stage zebrafish embryos, but also significantly reduced the magnitude of undesired deformations to the embryos during needle puncture and penetration from 61.0±12.1 μm for standard glass-pulled control microneedles to 42.4±11.5 μm for the POSS-enabled 3D microneedles (p < 0.01). In combination, these results suggest that wide-ranging biomedical fields could benefit from the presented 3D microinjection needles.
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Direct Printing of High-Resolution Metallic Three-Dimensional Microneedle Arrays Via Electrohydrodynamic Jet Printing
Abstract Three-dimensional (3D) microneedle arrays (MAs) have shown remarkable performances for a wide range of biomedical applications. Achieving advanced customizable 3D MAs for personalized research and treatment remain a formidable challenge. In this paper, we have developed a high-resolution electrohydrodynamic (EHD) 3D printing process for fabricating customizable 3D MAs with economical and biocompatible molten alloy. The critical printing parameters (i.e., voltage and pressure) on the printing process for both two-dimensional (2D) and 3D features are characterized, and an optimal set of printing parameters was obtained for printing 3D MAs. We have also studied the effect of the tip-nozzle separation speed on the final tip dimension, which will directly influence MAs' insertion performance and functions. With the optimal process parameters, we successfully EHD printed customizable 3D MAs with varying spacing distances and shank heights. A 3 × 3 customized 3D MAs configuration with various heights ranging from 0.8 mm to 1 mm and a spacing distance as small as 350 μm were successfully fabricated, in which the diameter of each individual microneedle was as small as 100 μm. A series of tests were conducted to evaluate the printed 3D MAs. The experimental results demonstrated that the printed 3D MAs exhibit good mechanical strength for implanting and good electrical properties for electrophysiological sensing and stimulation. All results show the potential applications of the EHD printing technique in fabricating cost-effective, customizable, high-performance MAs for biomedical applications.
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- Award ID(s):
- 2200200
- PAR ID:
- 10583100
- Publisher / Repository:
- American Society of Mechanical Engineers (ASME)
- Date Published:
- Journal Name:
- Journal of Micro and Nano Science and Engineering
- Volume:
- 12
- Issue:
- 2
- ISSN:
- 2994-7316
- Format(s):
- Medium: X
- Sponsoring Org:
- National Science Foundation
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- Free Publicly Accessible Full Text
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Accepted Manuscript1.0
- Journal Article:
- https://doi.org/10.1115/1.4065965
