Ai-enabled optimization of 3D-printed microneedles for simultaneous epidermal and dermal delivery

Conventional needle technologies are being revolutionized by nano- and micro-fabrication methods to create microneedles, organization of microscale needles on an array, which aim to reduce penetration pain and tissue damage while providing precise channels for administering bioagents and collecting body fluids. This thesis explores the advancements in 3D printing methods for microneedle fabrication and particularly focusing on their applications in biomedical engineering and healthcare. For the case of sampling body fluids, a finger-actuated microneedle array integrated with a microfluidic chip was visualized for simple and efficient self-collection of blood and interstitial fluid, eliminating the need for healthcare workers. The processes of fluid extraction and flow within the device were simulated to optimize efficiency. The thesis also explores the integration of artificial intelligence in 3D printing of microneedles, using machine learning and deep learning algorithms to optimize manufacturing processes and predict fabrication outcomes. This multidisciplinary approach enhances the quality control and precision of biodegradable microneedles fabricated through fused deposition modeling 3D printing and chemical etching. In the context of biomedical applications, for the case of Basal Cell Carcinoma skin cancer treatment, microneedles loaded with Marshmallow root extract and Imiquimod are explored, offering controlled release and targeted delivery with minimal side effects. This approach enhances therapeutic efficacy while minimizing patient discomfort and infection risks. Another significant focus is on the customization of microneedle arrays for treating various skin diseases, such as skin cancers and infections, which occur at different skin depths. By engineering the design of the microneedles in nonlinear ways with diverse needle heights on the array, the thesis introduces concurrent drug delivery to various skin layers. Additionally, varying the base diameter of the needles in the array facilitates prolonged or intermittent drug release, depending on the biodegradation kinetics of these needles. This approach enabled long-lasting simultaneous epidermal and dermal drug delivery. The thesis concludes that microneedle arrays hold significant potential in drug delivery due to their ability to administer treatments in a painless and minimally invasive manner, paving the way for more personalized and advanced healthcare solutions.