CORE SHELL NEEDLE ACTIVATOR

The method of claim 15, further comprising coating a supporting array with a water soluble polymer and contacting the supporting array with the cap assembly.ġ8. The method of claim 15, further comprising applying heat to bond the cap assembly to the core microneedle assembly.ġ7. The method of claim 6, further comprising generating a cap assembly by filling a plurality of cavities in a third silicone mold with a copolymer to form a plurality of caps, spinning the third silicone mold to remove a third scum layer of the copolymer on the third silicone mold, removing the molded caps from the third mold and transferring the molded caps onto the core microneedle assembly, and aligning the cap assembly with the core microneedle assembly to thereby cover the cores in the core microneedle assembly with the caps.ġ6. The method of claim 13, wherein the polymeric carrier is Polyvinylpyrrolidone (PVP).ġ5. The method of claim 6, wherein the therapeutic agent is mixed with a polymeric carrier of biocompatible or biodegradable polymers.ġ4.

The method of claim 6, further comprising dropping water on the second scum layer to remove the second scum layer while spinning the second silicone mold.ġ3. The method of claim 10, wherein the solvent is acetone.ġ2. The method of claim 6, further comprising dropping a solvent on the first scum layer to remove the scum layer while spinning the first silicone mold.ġ1. The method of claim 6, further comprising generating the first silicone mold by pouring polydimethylsiloxane (PDMS) over a master structure and curing.ġ0. The method of claim 6, wherein the copolymer is Poly(D,L-lactide-co-glycolide) (PLGA).ĩ. The method of claim 6, wherein the cavities in the first silicone mold and the second silicone mold are conical shaped.Ĩ.

A method of manufacturing a microneedle assembly, the method comprising: generating a core microneedle assembly by filling a first silicone mold including a plurality of microneedle cavities with a copolymer, spinning the first silicone mold to remove a first scum layer of the copolymer on the first silicone mold, and generating a core in each of the copolymer-filled cavities generating a therapeutic agent assembly by filling a plurality of cavities in a second silicone mold with a therapeutic agent, spinning the second silicone mold to remove a second scum layer of the therapeutic agent, and removing the molded therapeutic agent from the second mold and transferring the molded therapeutic agent to a substrate and aligning the therapeutic agent assembly with the core microneedle assembly to thereby fill the cores in the core microneedle assembly with the therapeutic agent.ħ. The system of claim 1, wherein the therapeutic agent is a vaccine.Ħ.

CORE SHELL NEEDLE ACTIVATOR

The system of claim 5, further comprising an activator in electronic communication with the computer processor to initiate the release of the therapeutic agent.ĥ. The system of claim 1, further comprising a computer processor in electronic communication with the microneedle assembly, the computer processor programmed with computer readable instructions to initiate the release of the therapeutic agent.Ĥ. The system of claim 1, wherein the biodegradable polymer degrades over time to release the therapeutic agent into the patient.ģ.

A pulsatile drug delivery system comprising: a microneedle assembly including a plurality of microneedles filled with a therapeutic agent, the microneedles comprising biodegradable polymers, the microneedle assembly configured to release the therapeutic agent at predetermined times with a predetermined amount of the therapeutic agent while the microneedle assembly remains embedded in a patient.Ģ.

Core shell needle