Method and apparatus for manufacturing a device

Abstract

A device, preferably a micro-device, is molded from a plastic material by injection molding, compression molding or embossing. A microabrader can be molded having microneedles for abrading the stratum corneum of the skin to form an abraded site in the tissue for enhancing drug delivery. The micro-device is molded using a mold assembly having a silicon molding surface. The silicon molding surface can include a recess corresponding to the desired shape and length of the microneedles. The silicon molding surface enables micron and submicron size features to be molded from polymeric materials without the polymeric material adhering to the mold surface. Micro-devices having molded features having micron and submicron dimensions can be rapidly produced without the use of a release agent.

1 . A microabrader for delivering a substance into skin, said microabrader comprising an abrading surface, wherein said abrading surface comprises frustoconical or frustopyramidal microprotrusions comprising at least one scraping edge and projecting from said abrading surface, and an effective amount of said substance.  
   
   
       2 . The microabrader of  claim 1  that further comprises a base comprising an abrading facet adapted to receive or integral with said abrading surface.  
   
   
       3 . The microabrader of  claim 2  that further comprises a handle attachment facet suitable for attaching a handle to said base.  
   
   
       4 . The microabrader of  claim 2 , wherein said abrading surface projects from said abrading facet.  
   
   
       5 . The microabrader of  claim 1 , wherein said microprotrusions are of a length sufficient to penetrate into the stratum corneum layer of said skin.  
   
   
       6 . The microabrader of  claim 1 , wherein said microprotrusions comprise at least two scraping edges.  
   
   
       7 . The microabrader of  claim 1 , wherein said microprotrusions comprise at least three facets and wherein the intersection of any two of said facets forms a scraping edge.  
   
   
       8 . The microabrader of  claim 1 , wherein said microprotrusions have microprotrusion bases and are constructed and arranged in a pattern such that the distance between the centers of said microprotrusion bases is at least two times the length of said microprotrusion.  
   
   
       9 . The microabrader of  claim 1 , wherein the microprotrusions are arranged in a pattern.  
   
   
       10 . The microabrader of  claim 9  wherein said pattern consists of rows and columns.  
   
   
       11 . The microabrader of  claim 9 , wherein said pattern is a circular pattern.  
   
   
       12 . The microabrader of  claim 9 , wherein said pattern is a random pattern.  
   
   
       13 . The microabrader of  claim 8 , wherein said bases of said microprotrusions are spaced apart to form valleys between said microprotrusions.  
   
   
       14 . The microabrader of  claim 1  having a coating of a bioactive substance on said abrading surface.  
   
   
       15 . The microabrader of  claim 14 , wherein said bioactive substance is a medicament.  
   
   
       16 . The microabrader of  claim 14 , wherein said bioactive substance is a vaccine.  
   
   
       17 . The microabrader of  claim 1 , wherein the length of said microprotrusions are greater than the depth to which they penetrate into said skin.  
   
   
       18 . The microabrader of  claim 1 , wherein said microprotrusions are of a length sufficient to penetrate through the stratum corneum layer of said skin when used to abrade said skin.