Sawtooth-shaped microsaws for enhanced transdermal drug delivery: Improved drug loading and piercing efficiency

This study presents a novel approach to transdermal drug delivery with the introduction of sawtooth-shaped MicroSaws (MSs), a bioinspired microneedle design that significantly enhances drug loading and piercing efficiency. Unlike traditional microneedles (MNs), MSs, with dimensions of 0.2 mm width, 0.4 mm length, and 0.65 mm height, are engineered using epoxy acrylate (EA) via digital light processing (DLP) 3D printing and coated with polyethylene glycol diacrylate (PEGDA) to ensure biocompatibility. Experimental results demonstrate that MSs outperform conventional MNs in both mechanical piercing tests and drug release studies, showcasing a 30 % increase in drug loading capacity and a 25 % improvement in pierceability. The unique sawtooth design not only facilitates deeper penetration but also creates microchannels that enhance drug diffusion across the stratum corneum. This innovation in microneedle technology holds significant promise for improving patient compliance and therapeutic outcomes in transdermal drug delivery systems. [Display omitted]