Customizable Fabrication of Photothermal Microneedles with Plasmonic Nanoparticles Using Low-Cost Stereolithography Three-Dimensional Printing.

Photothermal microneedle (MN) arrays have the potential to improve the treatment of various skin conditions such as bacterial skin infections. However, the fabrication of photothermal MN arrays relies on time-consuming and potentially expensive microfabrication and molding techniques, which limits their size and translation to clinical application. Furthermore, the traditional mold-and-casting method is often limited in terms of the size customizability of the photothermal array. To overcome these challenges, we fabricated photothermal MN arrays directly via 3D-printing using plasmonic Ag/SiO2 (2 wt % SiO2) nanoaggregates dispersed in ultraviolet photocurable resin on a commercial low-cost liquid crystal display stereolithography printer. We successfully printed MN arrays in a single print with a translucent, nanoparticle-free support layer and photothermal MNs incorporating plasmonic nanoaggregates in a selective fashion. The photothermal MN arrays showed sufficient mechanical strength and heating efficiency to increase the intradermal temperature to clinically relevant temperatures. Finally, we explored the potential of photothermal MN arrays to improve antibacterial therapy by killing two bacterial species commonly found in skin infections. To the best of our knowledge, this is the first time describing the printing of photothermal MNs in a single step. The process introduced here allows for the translatable fabrication of photothermal MN arrays with customizable dimensions that can be applied to the treatment of various skin conditions such as bacterial infections.

Highly Efficient Near-IR Photothermal Microneedles with Flame-Made Plasmonic Nanoaggregates for Reduced Intradermal Nanoparticle Deposition.

Near-infrared (NIR) photothermal therapy by microneedles (MNs) exhibits high potential against skin diseases. However, high costs, photobleaching of organic agents, low long-term stability, and potential nanotoxicity limit the clinical translation of photothermal MNs. Here, photothermal MNs are developed by utilizing Au nanoaggregates made by flame aerosol technology and incorporated in water-insoluble polymer matrix to reduce intradermal nanoparticle (NP) deposition. The individual Au interparticle distance and plasmonic coupling within the nanoaggregates are controlled by the addition of a spacer during their synthesis rendering the Au nanoaggregates highly efficient NIR photothermal agents. In situ aerosol deposition of Au nanoaggregates on MN molds results in the fabrication of photothermal MNs with thin plasmonic layers. The photothermal performance of these MN arrays is compared to ones made by three methods utilizing NP dispersions, and it is found that similar temperatures are reached with 28-fold lower Au mass due to reduced light scattering losses of the thin layers. Finally, all developed photothermal MN arrays here cause clinically relevant hyperthermia at benign laser intensities while reducing intradermal NP deposition 127-fold compared to conventional MNs made with water-soluble polymers. Such rational design of photothermal MNs requiring low laser intensities and minimal NP intradermal accumulation sets the basis for their safe clinical translation.