Macroporous solid hard microneedles with embedded particulate drugs

A microneedle drug delivery system for drug delivery via diffusion mediated by interstitial fluid, said microneedle drug delivery system comprising a solid material comprising:

• a solidified form obtained from a flowable material, the flowable material comprising a resin and a drug in particulate form;
• and
• the solidified form comprising a resin matrix comprising a plurality of pores in the resin matrix formed by spatial exclusion imposed by the presence of the drug in particulate form, wherein the plurality of pores are interconnected and distributed throughout the solidified form, the drug in particulate form being contained within the plurality of pores;
• wherein
• the particulate form is a powder, the powder comprising particles having sizes below 100 micrometers in a largest dimension.

A method of providing time-controlled delivery of a drug, said method comprising:

• providing a solid material comprising a solidified form obtained from a flowable material, the flowable material comprising a resin and a drug in particulate form, the solid material comprising a resin matrix and a plurality of pores in the resin matrix formed by spatial exclusion imposed by the presence of the drug in particulate form, wherein the plurality of pores are interconnected and distributed throughout the solidified form;
• the drug being contained within the plurality of pores;
• and
• permitting the solid material to come into contact with a dermal environment that comprises interstitial fluid, such that interstitial fluid contacts the drug in particulate form, causing the drug to dissolve into the interstitial fluid;
• wherein the particulate form is a powder, the powder comprising particles having sizes below 100 micrometers in a largest dimension.

A microneedle patch for transdermal drug delivery, comprising:

• a solid microneedle formed from a flowable material comprising a biocompatible resin and a drug in particulate form, the solid microneedle comprising a resin matrix and a plurality of pores in the resin matrix formed by spatial exclusion imposed by the presence of the drug in particulate form, wherein the plurality of pores are interconnected and distributed throughout the microneedle, the drug being embedded in the pores of the microneedle, the microneedle having a mechanical strength sufficient to penetrate the epidermis of skin without breaking;
• and
• a conformable back substrate bonded to the microneedle;
• wherein the particulate form is a powder, the powder comprising particles having sizes below about 100 micrometers in a largest dimension.