State of the Art in Constructing Gas-Propelled Dissolving Microneedles for Significantly Enhanced Drug-Loading and Delivery Efficiency

This study explores the development of microparticle-embedded gas-propelled dissolving microneedles (MNs) to enhance drug-loading and transdermal delivery efficiency, addressing limitations in current MN applications. The research systematically examines mold production and micromolding technologies, finding that 3D printing produces the most accurate male molds, while silica gel with lower Shore hardness yields higher demolding needle percentages (DNP) for female molds. Vacuum micromolding with optimized pressure outperforms centrifugation micromolding, resulting in improved DNP and needle morphology. The study identifies optimal materials for the needle skeleton, drug particle carrier, and pneumatic initiators, achieving a 1.35-fold increase in drug loading and a 1.19-fold increase in transdermal permeability compared to traditional MNs. This research offers comprehensive guidance for producing MNs with enhanced productivity, drug loading, and delivery efficiency.