A Single-Administration Microneedle Skin Patch for Multi-Burst Release of Vaccine against SARS-CoV-2

Elastic osmotic capsules mimic bolus injection with high release at delayed burst

The need for repeated administration of vaccines is costly, logistically challenging and leads to reduced compliance. Osmosis-driven swelling and rupture has been proposed as a mechanism for delayed burst release to mimic follow-up (booster) injections without requiring further intervention. The use of microparticles does not guarantee a single bolus release, and previous studies using monolithic implants failed to demonstrate high instant release at the moment of burst. In this study we developed elastic capsules based on a caprolactone-lactide copolymer that released 75 ± 8 % of their contents instantly after up to several weeks of incubation. Capsules swelled up to 5x their original mass through highly reproducible osmosis-induced water uptake. The water uptake rates depended on osmotic strength and could be approximated with a numerical model revealing a water permeability of 3.6 ± 0.2 mm2/(Pa∙day) for all 118 capsules. The moment of burst depended on osmotic strength and capsule stiffness (median times varied from 16 to 37 days) and showed large scatter. The capsule material was non-toxic to a macrophage cell line and degraded through bulk hydrolysis, with an extrapolated completion time of 8 months. The capsules were administered successfully in bovine cadavers with a widely used applicator.

Enhancing vaccine stability in transdermal microneedle platforms

Micron-scale needles, so-called microneedles (MNs) offer a minimally invasive, nearly painless, and user-friendly method for effective intradermal immunization. Maintaining the stability of antigens and therapeutics is the primary challenge in producing vaccine or drug-loaded MNs. The manufacturing of MNs patches involves processes at ambient or higher temperatures and various physio-mechanical stresses that can impact the therapeutic efficacy of sensitive biologics or vaccines. Therefore, it is crucial to develop techniques that safeguard vaccines and other biological payloads within MNs. Despite growing research interest in deploying MNs as an efficient tool for delivering vaccines, there is no comprehensive review that integrates the strategies and efforts to preserve the thermostability of vaccine payloads to ensure compatibility with MNs fabrication. The discussion delves into various physical and chemical approaches for stabilizing antigens in vaccine formulations, which are subsequently integrated into the MNs matrix. The primary focus is to comprehensively examine the challenges associated with the translation of thermostable vaccine MNs for clinical applications while considering a safe, cost-effective approach with a regulatory roadmap. The recent cutting-edge advances facilitating flexible and scalable manufacturing of stabilized MNs patches have been emphasized. In conclusion, the ability to stabilize vaccines and therapeutics for MNs applications could bolster the effectiveness, safety and user-compliance for various drugs and vaccines, potentially offering a substantial impact on global public health.

Transdermal delivery of PeptiCRAd cancer vaccine using microneedle patches

Microneedles (MNs) are a prospective system in cancer immunotherapy to overcome barriers regarding proper antigen delivery and presentation. This study aims at identifying the potential of MNs for the delivery of Peptide-coated Conditionally Replicating Adenoviruses (PeptiCRAd), whereby peptides enhance the immunogenic properties of adenoviruses presenting tumor associated antigens. The combination of PeptiCRAd with MNs containing polyvinylpyrrolidone and sucrose was tested for the preservation of structure, induction of immune response, and tumor eradication. The findings indicated that MN-delivered PeptiCRAd was effective in peptide presentation in vivo, leading to complete tumor rejection when mice were pre-vaccinated. A rise in the cDC1 population in the lymph nodes of the MN treated mice led to an increase in the effector memory T cells in the body. Thus, the results of this study demonstrate that the combination of MN technology with PeptiCRAd may provide a safer, more tolerable, and efficient approach to cancer immunotherapy, potentially translatable to other therapeutic applications.

Microneedles: multifunctional devices for drug delivery, body fluid extraction, and bio-sensing

Microneedles represent a miniaturized mechanical structure with versatile applications, including transdermal drug delivery, vaccination, body-fluid extraction, and bio-sensing. Over the past two decades, microneedle-based devices have garnered considerable attention in the biomedicine field, exhibiting the potential for mitigating patient discomfort, enhancing treatment adherence, avoiding first-pass effects, and facilitating precise therapeutic interventions. As an application-oriented technology, the innovation of microneedles is generally carried out in response to a specific demand. Currently, three most common applications of microneedles are drug delivery, fluid extraction, and bio-sensing. This review focuses on the progress in the materials, fabrication techniques, and design of microneedles in recent years. On this basis, the progress and innovation of microneedles in the current research stage are introduced in terms of their three main applications.

Beyond Needles: Immunomodulatory Hydrogel-Guided Vaccine Delivery Systems

Vaccines are critical for combating infectious diseases, saving millions of lives worldwide each year. Effective immunization requires precise vaccine delivery to ensure proper antigen transport and robust immune activation. Traditional vaccine delivery systems, however, face significant challenges, including low immunogenicity and undesirable inflammatory reactions, limiting their efficiency. Encapsulating or binding vaccines within biomaterials has emerged as a promising strategy to overcome these limitations. Among biomaterials, hydrogels have gained considerable attention for their biocompatibility, ability to interact with biological systems, and potential to modulate immune responses. Hydrogels offer a materials science-driven approach for targeted vaccine delivery, addressing the shortcomings of conventional methods while enhancing vaccine efficacy. This review examines the potential of hydrogel-based systems to improve immunogenicity and explores their dual role as immunomodulatory adjuvants. Innovative delivery methods, such as microneedles, patches, and inhalable systems, are discussed as minimally invasive alternatives to traditional administration routes. Additionally, this review addresses critical challenges, including safety, scalability, and regulatory considerations, offering insights into hydrogel-guided strategies for eliciting targeted immune responses and advancing global immunization efforts.

Current Status of Microneedle Array Technology for Therapeutic Delivery: From Bench to Clinic

In recent years, microneedle (MN) patches have emerged as an alternative technology for transdermal delivery of various drugs, therapeutics proteins, and vaccines. Therefore, there is an urgent need to understand the status of MN-based therapeutics. The article aims to illustrate the current status of microneedle array technology for therapeutic delivery through a comprehensive review. However, the PubMed search was performed to understand the MN's therapeutics delivery status. At the same time, the search shows the number no of publications on MN is increasing (63). The search was performed with the keywords "Coated microneedle," "Hollow microneedle," "Dissolvable microneedle," and "Hydrogel microneedle," which also shows increasing trend. Similarly, the article highlighted the application of different microneedle arrays for treating different diseases. The article also illustrated the current status of different phases of MN-based therapeutics clinical trials. It discusses the delivery of different therapeutic molecules, such as drug molecule delivery, using microneedle array technology. The approach mainly discusses the delivery of different therapeutic molecules. The leading pharmaceutical companies that produce the microneedle array for therapeutic purposes have also been discussed. Finally, we discussed the limitations and future prospects of this technology.

Promising strategies for smart insulin delivery system: Glucose-sensitive microneedle

The diabetes treatment landscape is rapidly evolving towards intelligent and precise therapeutic interventions. Among these advancements, glucose-sensitive microneedle patches (GSMPs), which can automatically adjust the transdermal release rate of insulin based on glucose concentrations, are emerging as a promising strategy. In this work, a new classification method has been proposed for GSMPs, categorizing them into integrated, all-in-one, and core-shell structures. The working mechanism and performance of GSMPs are thoroughly analyzed to compare the advantages and disadvantages of these three forms. The correlation between glucose-sensitive performance and normal blood glucose maintenance time (NGT) is further explored. Our findings indicate that all-in-one GSMPs demonstrate a positive correlation between in vitro glucose-sensitive controlled-release performance and NGT, unlike assembled GSMPs, where the performance is influenced by the matrix material and crosslinking factors. Simultaneously, challenges in clinical translation and future development trends are discussed from a patient's perspective. In summary, the new classification method, in-depth explanation of mechanisms, and analysis of challenges in this work contribute to a better understanding of the field of GSMPs and provide guidance for the development of more advanced and efficient GSMPs.

Single-Administration Self-Boosting Microneedle Patch for The Treatment of Obesity

Glucagon-like peptide-1 receptor agonists (GLP-1 RAs) are one of the most effective treatments for obesity. The current therapy associated with repeated subcutaneous injections to maintain the drug therapeutic effect causes patient compliance issues and raises environmental concerns (due to sharp biohazard waste from disposed syringes/needles). Herein, we report a programmable scheduled release microneedles (PSR-MNs) system for delivering Semaglutide (a GLP-1 RA agent with a half-life of ~ 7 days) to manage and treat obesity. A single skin administration of a PSR-MNs patch (2 cm × 2 cm) which contains 4 programmable core-shell MNs patches (1 cm2 each, so-called pixels) enables the repeated release of Semaglutide every 7 days and sustains the drug efficacy for an unprecedented one-month period, simulating the effect of using four bolus injections spaced 7 days apart. Our PSR-MNs system provides an advanced injection-free platform to significantly enhance the current treatment of obesity with GLP-1RAs, addressing concerns related to pain, needle phobia, high cost and the need of medical facilities/personnel in traditional injections to administer the drug.

Demonstration of Tunable Control over a Delayed-Release Vaccine Using Atomic Layer Deposition

Many vaccines require multiple doses for full efficacy, posing a barrier for patient adherence and protection. One solution to achieve full vaccination may be attained with single-administration vaccines containing multiple controlled release doses. In this study, delayed-release vaccines were generated using atomic layer deposition (ALD) to coat antigen-containing powders with alumina. Using in vitro and in vivo methods, we show that increasing the coat thickness controls the kinetics of antigen release and antibody response, ranging from weeks to months. Our results establish an in vitro-in vivo correlation with a level of tunable control over the antigen release and antibody response times with the potential to impact future vaccine design.

Multilayered Microneedles for Triphasic Controlled Delivery of Small Molecules and Proteins

Transdermal delivery is an attractive delivery method that increases bioavailability, is suitable for a wide variety of therapeutics, and offers stable delivery outcomes. However, many therapeutics are unable to readily cross the stratum corneum. Microneedles mechanically disrupt the cutaneous barrier to deliver small molecules, proteins, and vaccines. To date, microneedles have not been used in conjunction with coacervate, a liquid-liquid phase separation that protects unstable proteins. A three-layer microneedle for the controlled release of three different molecules is designed. Through micromolding, microneedles are efficiently generated, which benefits product scalability. The microneedles have good mechanical integrity and effectively penetrate porcine skin ex vivo. The three layers, in the microneedles, release the cargo in a three-phase manner. The released protein maintains its structure well. Moreover, layer thickness can be controlled by varying fabrication parameters. The microneedles can incorporate both small molecule drugs and protein therapeutics, thus promising uses in multi-drug therapies through a single treatment.

Accelerated cascade melanoma therapy using enzyme-nanozyme-integrated dissolvable polymeric microneedles

Dissolvable polymeric microneedles (DPMNs) have emerged as a powerful technology for the localized treatment of diseases, such as melanoma. Herein, we fabricated a DPMN patch containing a potent enzyme-nanozyme composite that transforms the upregulated glucose consumption of cancerous cells into lethal reactive oxygen species via a cascade reaction accelerated by endogenous chloride ions and external near-infrared (NIR) irradiation. This was accomplished by combining glucose oxidase (Gox) with a NIR-responsive chloroperoxidase-like copper sulfide (CuS) nanozyme. In contrast with subcutaneous injection, the microneedle system highly localizes the treatment, enhancing nanomedicine uptake by the tumor and reducing its systemic exposure to the kidneys and spleen. NIR irradiation further controls the potency and toxicity of the formulation by thermally disabling Gox. In a mouse melanoma model, this unique combination of photothermal, starvation, and chemodynamic therapies resulted in complete tumor eradication (99.2 ± 0.8 % reduction in tumor volume within 10 d) without producing signs of systemic toxicity. By comparison, other treatment combinations only resulted in a 42-76.5 % reduction in tumor growth. The microneedle patch design is therefore not only highly potent but also with regulated toxicity and improved safety.