Methods are provided that involve the intentional and controlled precipitation of a drug or active agent, or a reduction of solubility of a polymer or other film-forming component of a formulation, or a combination of both methods, to improve the processes for making microneedles or other objects by casting into molds and the resulting parts produced by casting. The selective reduction in solubility of formulation components solves many problems associated with the casting of polymer formulations into molds. The methods are preferably adapted for making microneedles of biodegradable polymer and drug composites, and may also be used to produce other solid objects formed by casting into molds of compositions containing polymers and active agents.

Systems and methods are provided for fabricating microneedle arrays that includes electrospun fibers preferentially disposed within the microneedles of the array. Providing the electrospun fibers preferentially in the microneedles allows for more of a drug or other substance present in the fibers to be deposited into tissue or to provide other benefits. A mold for forming the microneedle arrays includes an insulating surface layer. The insulating surface layer affects the electric field during electrospinning such that electrospun fibers are deposited preferentially within the microneedle cavities of the mold relative to the surface of the mold. A bulk material can then be applied to the mold to form the bulk of the microneedles with electrospun fibers embedded within and a backing layer to which the microneedles are attached.

A handling system and/or a grouping unit of a handling system and a method for handling individual parts that have to be removed from a preceding production process, in particular injection-molded parts in the form of pipette tips that are produced in groups in an injection molding machine with a multiple tool and must be removed from the multiple tool for the further handling, the multiple tool including at least one distributing star having a plurality of mold cavities, whereby a removal arrangement is defined by the multiple tool for the further handling of the injection-molded parts. The method includes removing the finished injection molded parts, loading the parts into a grouping unit to produce a grid arrangement, and removing the parts from one grouping unit with a second grouping unit.

The present disclosure relates to an apparatus and a process which can continuously produce microneedles using a conveyor system and decomposition or vacuum. By using the microneedle production method and apparatus according to the present disclosure, continuous mass production of microneedles is available, and therefore it is possible to reduce the input of manpower and produce a large amount of products compared to the conventional production method.

A needle-equipped outer cylinder includes: a needle tube; a joining member comprising: a needle tube accommodation hole that accommodates a proximal end side portion of the needle tube and penetrates the joining member from a distal end of the joining member to a proximal end of the joining member, and a joining outer peripheral portion provided on an outer peripheral portion of the needle tube accommodation hole; and an outer cylinder member comprising: a distal end joint that comprises an inner cavity that receives the joining outer peripheral portion of the joining member from a distal end side, and a projection located at a proximal end portion of the inner cavity and projecting into the inner cavity. The joining member comprises, at a proximal end portion of the joining member, an abutment portion that abuts the projection of the outer cylinder member.

In the preferred embodiment, a method of making microneedles comprises i) providing a microneedle template (300) having a plurality of microneedles cavities (360) on one surface, ii) preparing a casting solution (320) comprising at least one matrix material and its solvent, iii) subjecting said microneedle template (300) to a vacuum pressure for a length of time to deprive it of air, iv) dispensing the casting solution (320) over the air-deprived microneedle template, v) allowing the casting solution (320) to be drawn into the air-deprived microneedle cavities (360) completely, and vi) allowing the dissolving microneedles to solidify or dry in a controlled environment.

A device for producing microstructures, particularly microneedles and more particularly microneedle arrays, including a female mold that has, on a top side, at least one in particular conical depressed portion for producing a microstructure. The female mold is, for example, in the form of a silicone cap and is connected to a hollow cylinder in particular via a holding element. A plunger is disposed movably inside the hollow cylinder.

Disclosed herein are drug delivery devices that can temporally and spatially deliver biologically active agents. An example drug delivery device includes a microneedle array comprising a plurality of microneedles on a surface of a substrate, each microneedle comprising a core comprising a hydrogel and a layer on a surface of the core. Also disclosed are methods of using the drug delivery device, and methods of making the microneedle array that includes a loading device.

A microneedle array has a plurality of microneedles, said microneedles being supported by a substrate. In order to improve the properties of the microneedle array, the substrate is in the form of a grid structure or comprises a grid structure.

A needle guard grip device may include a body extending from a first end to a second end along a central longitudinal axis of the body. The body may include a plurality of ribs extending perpendicularly to the central longitudinal axis. The plurality of ribs may include a first set of longitudinally spaced ribs disposed on a first side of the central longitudinal axis, and a second set of longitudinally spaced ribs disposed on a second side of the central longitudinal axis that is opposite of the first side. Moving along the central longitudinal axis, ribs of the first set of longitudinally spaced ribs may alternate with ribs of the second set of longitudinally spaced ribs.