The development of a microneedle applicator for facial application
M.R. Moeskops (TU Delft - Industrial Design Engineering)
M.C. Dekker – Graduation committee member (TU Delft - Industrial Design Engineering)
G.A. Orsini – Mentor (TU Delft - Industrial Design Engineering)
Maarten Smit – Mentor (uPATCH)
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Abstract
Microneedle patch (MNP) technology enables transdermal drug delivery (TDD) by penetrating the stratum corneum (SC) and is upcoming in the East-Asian skincare market as anti-acne microneedle patches (AAMNPs). TDD increase the absorption of active acne-fighting ingredients, which are dissolved in these microneedles. However, AAMNPs cannot penetrate the SC successfully with manual application. As manual application frequently results in inconsistent needle penetration, reduced efficacy, and needle damage during use, which has also been confirmed with this thesis. To make the microneedles (MNs) penetrate an applicator is required. At the moment there is no known cosmetic MNP applicator on the market, indicating a gap in the market. This thesis presents the design and development of MINUS, a compact AAMNP applicator for facial use. The primary objective was to create a device that ensures effective, safe, consistent, and accurate application of AAMNPs while accommodating multiple patch sizes for a broad MNP usage. The project was conducted for uPATCH, a startup primarily focused on the development for medical MNP applicator.
The research is done with a triple diamond approach with three phases: research, conceptualisation, and embodiment. Main procedures included market analysis, investigating penetration mechanics, researching AAMNP effective penetration spring force and user evaluations. The resulting design implements an impact force delivery system, enabled by a spring that is retracted and locked by twisting the device. This spring is released by a button, pushing the inserting AAMNP forward, resulting in penetration using impact force. The design consists of nine parts that can be easily assembled under 1 minutes. The applicator accommodates AAMNPs up to 20mm in diameter and prioritizes compatibility with existing patch packaging for rapid market integration.
Findings indicate that the MINUS applicator successfully enables skin penetration of CMNPs, transforming previously ineffective topical applications into functional transdermal delivery systems. However, several limitations were identified, including testing conducted on forearm rather than facial skin, and the inability to establish direct contact with manufacturers and consumers for validation. Recommendations include exploring an adjustable impact force mechanism to accommodate for the different facial regions, investigating repairability improvements and encouraging MNP manufacturers to redesign their MNPs to be able to penetrate with a spring force of 20 N instead of 45 N.
This thesis shows that a well-designed applicator can significantly enhance the effectiveness and user experience of AAMNPs, creating value for manufacturers, clients, and end-users while addressing a clear gap in the current market.