Traditional insulin administration for people with diabetes often involves painful injections, leading to discomfort and challenges with patient compliance. A promising alternative to these conventional methods is transdermal insulin delivery using microneedle arrays, which offer a more comfortable way to deliver insulin through the skin. This study introduces an innovative approach using 3D-printed microneedle arrays coated with insulin via a dip-coating process. These microneedles present a compelling alternative to traditional injections, particularly due to their ability to gently pierce the stratum corneum, the outermost layer of skin, while minimizing discomfort. The microneedle arrays were fabricated using biocompatible resin polymers through 3D printing, creating solid conical needles with a length of 1200 µm, a base diameter of 200 µm, a tip diameter of 80 µm, and a needle spacing of 1.2 mm. The insulin coating was achieved by dip-coating the microneedles in a solution of insulin and polyvinyl alcohol (PVA), with careful optimization of the solution concentration, immersion time, and withdrawal speed to ensure a uniform and controlled coating thickness. Mechanical stability and skin penetration capabilities of the microneedles were assessed using skin models such as parafilm and porcine skin. The tests confirmed that the coated microneedles are robust enough to consistently penetrate the skin. In vivo studies with diabetic rats were conducted to evaluate skin irritation, penetration, and drug delivery efficiency. The insulin-coated microneedle arrays successfully penetrated the skin and delivered the drug with approximately 90 % efficiency. The study also showed that the microneedles provided consistent drug delivery, and the skin recovered without any signs of injury. Additionally, the hypoglycemic effect of the insulin-coated microneedles was comparable to that of traditional subcutaneous insulin injections. These findings underscore the potential of microneedle arrays as a painless and effective method for insulin delivery, maintaining stable glucose levels over an extended period. The demonstrated safety and efficacy of the coated microneedles open the door for clinical trials and potential use in diabetic patients, offering a promising advancement in diabetes management.
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