System and method for microneedle delivery of microencapsulated vaccine and bioactive proteins
A method for producing at least one microneedle containing a vaccine for transdermal delivery of the vaccine to a patient includes preparing microparticles or nanoparticles of encapsulated vaccine by preparing a solution comprising a vaccine antigen and a biocompatible polymer matrix; and spray drying the solution to form the microparticles or nanoparticles. The method includes the further steps of preparing a film composition including at least one pre-polymer solution; preparing a suspension comprising the microparticles or nanoparticles and the film composition; loading the suspension into a 3D printer; printing, via the 3D printer, at least one microneedle made from the suspension; and, converting the pre-polymer solution into a cross-linked biopolymer by exposing the at least one microneedle to UV light. Also disclosed are microneedles containing a vaccine for transdermal delivery.
1. A method of producing at least one microneedle comprising a vaccine for transdermal delivery of the vaccine to a patient, comprising:
(a) preparing microparticles or nanoparticles of encapsulated vaccine by:
(i) preparing a solution comprising a vaccine antigen and a biocompatible polymer matrix; and
(ii) spray drying the solution to form the microparticles or nanoparticles;
(b) preparing a film composition comprising at least one pre-polymer solution, wherein the at least one pre-polymer solution comprises poly(ethylene glycol)diacrylate (PEGDA);
(c) preparing a suspension comprising the microparticles or nanoparticles and the film composition;
(d) loading the suspension into a 3D printer;
(e) printing, via the 3D printer, at least one microneedle comprising the suspension; and,
(f) converting the pre-polymer solution into a cross-linked biopolymer by exposing the at least one microneedle to UV light.
2. The method of claim 1 , wherein the film composition further comprises polyvinylpyrrolidone, a photo-initiator, and a surfactant.
3. The method of claim 2 , wherein the film composition further comprises a sugar or sodium bicarbonate.
4. The method of claim 1 , wherein the microparticles or nanoparticles comprise an adjuvant.
5. The method of claim 1 , wherein the biocompatible polymer matrix comprises albumin cross-linked with glutaraldehyde.
6. The method of claim 1 , wherein the at least one microneedle comprises an array comprising a plurality of microneedles.
7. The method of claim 1 , wherein printing the array of microneedles via the 3D printer comprises dispensing, via the 3D printer, the suspension into a mold configured to form the microneedles.
8. The method of claim 1 , wherein exposing the at least one microneedle to UV light comprises exposing the at least one microneedle to UV light having a wavelength in the range of about 365 nm to about 405 nm.
9. The method of claim 1 , wherein the vaccine antigen comprises the S-1 spike protein of SARS-CoV-2 virus or heat-inactivated SARS-CoV-2 virus.
10. A method of transdermal delivery of a vaccine, comprising:
providing the at least one microneedle of claim 1 ; and
(b) injecting the encapsulated microparticles or nanoparticles transdermally through the at least one microneedle by applying the microneedle to the skin of a patient and allowing the film composition to biodegrade, thereby releasing the encapsulated microparticles or nanoparticles into the skin, whereby the encapsulated vaccine retains bioactivity after cellular uptake.
11. A microneedle for transdermal delivery of a bioactive material, comprising:
a plurality of microneedles comprising:
(a) a film composition comprising a cross-linked biopolymer; and
(b) encapsulated microparticles or nanoparticles comprising a bioactive material and a biocompatible polymer matrix suspended within the film composition,
wherein the film composition is configured to biodegrade and transdermally inject the vaccine when applied to the skin of a patient, whereby the encapsulated vaccine retains bioactivity after cellular uptake,
wherein printing the plurality of microneedles via the 3D printer comprises dispensing, via the 3D printer, the suspension into a mold configured to form the microneedles.
12. The microneedle of claim 11 , wherein pre-polymer solution comprises poly(ethylene glycol)diacrylate (PEGDA).
13. The microneedle of claim 11 , wherein the film composition further comprises polyvinylpyrrolidone, a photo-initiator, and a surfactant.
14. The microneedle of claim 13 , wherein the film composition further comprises a sugar or sodium bicarbonate.
15. The microneedle of claim 11 , wherein the microparticles or nanoparticles comprise an adjuvant.
16. The microneedle of claim 11 , wherein the biocompatible polymer matrix comprises albumin cross-linked with glutaraldehyde.
17. The microneedle of claim 11 , wherein the at least one microneedle comprises an array comprising a plurality of microneedles.
18. The microneedle of claim 11 , wherein the microneedles are configured to be exposed to UV light having a wavelength in the range of about 365 nm to about 405 nm.
19. The system of claim 11 , wherein the bioactive material comprises at least one vaccine antigen.
20. The system of claim 11 , wherein the at least one vaccine antigen comprises the S-1 spike protein of SARS-CoV-2 virus or heat-inactivated SARS-CoV-2 virus.
21. A microneedle for transdermal delivery of a bioactive material, comprising:
a plurality of microneedles comprising:
(a) a film composition comprising a cross-linked biopolymer; and
(b) encapsulated microparticles or nanoparticles comprising a bioactive material and a biocompatible polymer matrix suspended within the film composition,
wherein the film composition is configured to biodegrade and transdermally inject the vaccine when applied to the skin of a patient, whereby the encapsulated vaccine retains bioactivity after cellular uptake, and
wherein the at least one vaccine antigen comprises the S-1 spike protein of SARS-CoV-2 virus or heat-inactivated SARS-CoV-2 virus.