Several recent research efforts have focused on use of computer-aided additive fabrication technologies, commonly referred to as additive manufacturing, rapid prototyping, solid freeform fabrication, or three-dimensional printing technologies, to create structures for tissue engineering. For example, scaffolds for tissue engineering may be processed using rapid prototyping technologies, which serve as matrices for cell ingrowth, vascularization, as well as transport of nutrients and waste. Stereolithography is a photopolymerization-based rapid prototyping technology that involves computer-driven and spatially controlled irradiation of liquid resin. This technology enables structures with precise microscale features to be prepared directly from a computer model. In this review, use of stereolithography for processing trimethylene carbonate, polycaprolactone, and poly(D,L-lactide) poly(propylene fumarate)-based materials is considered. In addition, incorporation of bioceramic fillers for fabrication of bioceramic scaffolds is reviewed. Use of stereolithography for processing of patient-specific implantable scaffolds is also discussed. In addition, use of photopolymerization-based rapid prototyping technology, known as two-photon polymerization, for production of tissue engineering scaffolds with smaller features than conventional stereolithography technology is considered.

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The development of a microneedle-based biosensor array for multiplexed in situ detection of exercise-induced metabolic acidosis, tumor microenvironment, and other variations in tissue chemistry is described. Simultaneous and selective amperometric detection of pH, glucose, and lactate over a range of physiologically-relevant concentrations in complex media is demonstrated. Furthermore, materials modified with a cell-resistant (Lipidure®) coating were shown to inhibit macrophage adhesion; no signs of coating delamination were noted over a 48-hour period.

In this manuscript, recent advancements in the area of minimally-invasive transdermal biosensing and drug delivery are reviewed. The administration of therapeutic entities through the skin is complicated by the stratum corneum layer, which serves as a barrier to entry and retards bioavailability. A variety of strategies have been adopted for the enhancement of transdermal permeation for drug delivery and biosensing of various substances. Physical techniques such as iontophoresis, reverse iontophoresis, electroporation, and microneedles offer (a) electrical amplification for transdermal sensing of biomolecules and (b) transport of amphiphilic drug molecules to the targeted site in a minimally invasive manner. Iontophoretic delivery involves the application of low currents to the skin as well as the migration of polarized and neutral molecules across it. Transdermal biosensing via microneedles has emerged as a novel approach to replace hypodermic needles. In addition, microneedles have facilitated minimally invasive detection of analytes in body fluids. This review considers recent innovations in the structure and performance of transdermal systems.

Atomic layer deposition (ALD) is being used for deposition of conformal thin films on a variety of materials, including medical device materials and biologically derived materials. This review describes thin film deposition on materials using ALD for bioelectronic device, implantable device, biosensor, drug delivery device, tissue engineering scaffold and bioassay device applications. Recent advances in ALD technology, including low temperature ALD of thin films on temperature sensitive substrates, are considered. Finally, translation of ALD to commercial use, including use of ALD by the medical device industry, is described.

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Microneedles are minimally invasive transdermal medical devices that are utilized for various applications, including drug delivery, fluid sampling, micro-dialysis, and electrochemical sensing. These devices are associated with less pain and tissue damage as compared with conventional hypodermic needle-based devices. In this study, we demonstrate fabrication of titanium alloy microneedle arrays with nitrogen-incorporated ultrananocrystalline diamond (N-UNCD) coatings. Microneedles were micromachined from ASTM F136 ELI Ti-6Al-4V alloy, a widely used medical-grade titanium alloy. N-UNCD coatings were deposited on the microneedles using microwave plasma enhanced chemical vapor deposition to enhance mechanical strength, increase hardness, improve biocompatibility, and provide an electrochemically stable surface. The structural and chemical properties of the N-UNCD titanium alloy microneedle arrays were evaluated using scanning electron microscopy and Raman spectroscopy. The mechanical robustness and skin penetration capability of the devices were demonstrated using cadaveric porcine skin. Finally, the electrochemical properties of the N-UNCD electrodes were evaluated; in vitro electrochemical detection of uric acid and dopamine was demonstrated using unmodified N-UNCD electrodes.These results demonstrate the application potential of N-UNCD-coated titanium alloy microneedles for transdermal electrochemical biosensing applications.

Poly(glycolic acid) microneedle arrays were fabricated using a drawing lithography process; these arrays were modified with a drug release agent and an antifungal agent by piezoelectric inkjet printing. Coatings containing poly(methyl vinyl ether-co-maleic anhydride), a water-soluble drug release layer, and itraconazole (an antifungal agent), were applied to the microneedles by piezoelectric inkjet printing. Microscopic evaluation of the microneedles indicated that the modified microneedles contained the piezoelectric inkjet printing-deposited agents and that the surface coatings were released in porcine skin. Energy dispersive x-ray spectrometry aided in confirmation that the piezoelectric inkjet printing-deposited agents were successfully applied to the desired target areas of the microneedle surface. Fourier transform infrared spectroscopy was used to confirm the presence of the component materials in the piezoelectric inkjet printing-deposited material. Itraconazole-modified microneedle arrays incubated with agar plates containing Candida albicans cultures showed zones of growth inhibition.