3D microneedle patch could replace vaccine needle

The process of vaccination hasn’t evolved much over the past several decades. It still relies on a freeze-dried vaccine powder, stored under refrigeration, that has to be mixed into a liquid form and administered through an injection using a needle and syringe. However, researchers at Stanford University and the University of North Carolina at Chapel Hill may soon revolutionize this traditional approach. They have developed an innovative 3D-printed vaccine patch that not only eliminates the need for needles but also promises enhanced protection compared to conventional vaccines.

Applied directly to the skin, the microform patch would have generated an immune response 10 times greater than a vaccine administered into the arm muscle via a needle. The microneedle patch has other advantages, including easy and painless application and the possibility of self-administration.

3D microneedle patch could replace vaccine needle

“By developing this technology, we hope to lay the foundation for global and more rapid development of vaccines administered at lower doses, without pain and anxiety,” said Joseph DeSimone, lead author of the study.

“One of the biggest lessons we have learned during the pandemic is that innovation in science and technology can drive global change.

Vaccine patches consist of 3D printed micro-needles arranged on a polymer patch and are applied directly to the skin. The microneedle prototype is a collection of dozens of tiny needles lined up on a small patch. They are so small that each is measured in microns and is as thin as a human hair. The vaccine then targets immune cells in the skin and generates an antigen-specific antibody response.

Microneedle patches also offer logistical advantages. Vaccines administered by injection usually require storage in refrigerators or freezers and usually involve a trip to a clinic, hospital, or vaccination center. By contrast, vaccine patches can be shipped anywhere in the world without special handling, and because they can be self-administered, it would mean fewer trips to hospitals or clinics.

Scientists believe such benefits would increase vaccination rates in the future.

3D printing allows for greater customization and repeatability than traditional micromolding techniques and allows for the production of patches on demand. This eliminates the need for storage space in clinics and laboratories, resulting in reduced micromolding costs.

In 2018, for example, scientists at the University of Texas at Dallas developed a new low-cost method to make microneedle arrays using an FFF 3D printer, while in early 2021 researchers at Rutgers University used a micro-stereolithography technique to 4D print bioinspired programmable microneedles that improve tissue adhesion.

More recently, the University of Kent and the University of Strathclyde have produced a device combining 3D printing, microneedles and microelectromechanical systems (MEMS), which could be used to provide controlled transdermal drug release.