Method for injection molding manufacture of controlled release devices

A method for producing a device for controlled release of an active agent, comprising:

• i) injecting a first thermoset polymer into a mold cavity and effecting at least partial cross-linking of the first polymer;
• ii) injecting a second thermoset polymer containing the active agent into the mold.

A method for producing a device for controlled release of a plurality of active agents, comprising:

• i) injecting a first thermoset polymer into a mold cavity and effecting at least partial cross-linking of the first polymer;
• ii) injecting a second thermoset polymer containing a first active agent into the mold;
• iii) after injecting the second polymer, injecting a third thermoset polymer containing a second active agent into the mold.

A method of producing a device for controlled release of a plurality of active agents, in a mold cavity having a plurality of injection gate openings, comprising:

• i) injecting for a first time interval, a first thermoset polymer into the mold cavity through a first gate opening, and a second thermoset polymer through a second gate opening,
• ii) injecting, for a second time interval, thermoset polymer containing a first active agent into the mold cavity through the first gate opening, and thermoset polymer containing a second active agent through the second gate opening.

A controlled release device comprising a core of thermoset polymer containing at least one active agent surrounded by a thermoset polymer sheath of non-uniform thickness.

A cylindrical rod comprising a core of thermoset polymer containing at least one active agent, surrounded by a thermoset polymer sheath, wherein the thickness of sheath varies along the length of the rod.

An intravaginal ring comprising a core of thermoset polymer containing at least one active agent, surrounded by a thermoset polymer sheath, wherein the thickness of sheath varies along the circumference of the ring.