Method of fabricating porous membrane with unique pore structure for aerosolized delivery of drugs

A method, comprising the steps of:

• providing a laser source;
• providing a thin, flexible polymeric sheet material comprised of a polymer selected from the group consisting of polycarbonates, polyimides, polyethers, polyether imides, polyethylene and polyesters;
• directing a pulse of laser energy onto a first surface of the material thereby drilling a pore through the material, whereby the pore has a substantially circular cross-section;
• repeating the drilling a plurality of times thereby creating a plurality of pores each extending through the material, wherein each of the plurality of pores has a size deviation from pore to pore in an amount of less than about 10%;
• wherein each of the pores has an unflexed exit aperture diameter in the range of about 0.5 to about 50 microns which pores are positioned at a distance in the range of about 30 to about 70 microns apart from each other;
• wherein the drilling is carried out in a manner so as to create an elevated area surrounding each said exit aperture of the pores, the elevated areas projecting above the polymeric sheet material surrounding the elevated areas.