Nanoscale Additive Manufacturing of Buccal Microneedle Patches for Enhanced Trans-Mucosal Drug Transport

Buccal drug delivery offers a promising, non-invasive route for the systemic administration of both small-molecule and biologic therapeutics. To date however, its broader clinical utility is limited by poor permeability of the oral mucosa and enzymatic degradation within the oral cavity. Microneedle (MN) technologies are well established in transdermal delivery and provide a compelling strategy to overcome these barriers, yet their application to buccal tissues remains underexplored. This project aims to advance buccal drug delivery through the design, fabrication, and evaluation of highly precise microneedle patches produced using additive manufacturing techniques. These will include two-photon polymerisation (2PP) using the CELLINK Nanoscribe Quantum X bio 3D printer at Aston University, the first of its kind to be installed by Nanoscribe in the UK.

The first objective will engineer microneedle geometries optimised for buccal tissue insertion, mechanical resilience, and release profile. By tailoring microstructures, the study will identify design parameters that enable reliable penetration of the keratinised and non-keratinised regions of the oral mucosa with minimal patient discomfort and risk of adverse effects. To support systematic optimisation, a structured Design of Experiments (DOE) approach will be employed. Material selection will focus on biocompatible, photopolymerisable resins suitable for drug loading or for forming drug-containing matrices.

The second objective is to investigate the capacity of these MN systems to deliver both small-molecule compounds and biologics. Encapsulation strategies, including matrix-loaded, dip-coated, and layered designs, will be evaluated for stability, release kinetics, and compatibility. In vitro permeation studies using buccal models will quantify enhancement in trans-mucosal transport, while analytical assays will assess formulation integrity post-fabrication and post-delivery.

Anticipated project outcomes will demonstrate how 2PP-engineered microneedle patches can significantly enhance buccal delivery of diverse therapeutics. This work will provide a platform to support future translational development of minimally invasive, patient-friendly buccal delivery platforms.

Curti, C., Kirby, D.J. and Russell, C.A., 2020. Current formulation approaches in design and development of solid oral dosage forms through three-dimensional printing. Progress in Additive Manufacturing, 5(2), pp.111-123.

Curti, C., Kirby, D.J. and Russell, C.A., 2021. Stereolithography apparatus evolution: enhancing throughput and efficiency of pharmaceutical formulation development. Pharmaceutics, 13(5), p.616.

Curti, C., Kirby, D.J. and Russell, C.A., 2024. Systematic screening of photopolymer resins for stereolithography (SLA) 3D printing of solid oral dosage forms: Investigation of formulation factors on printability outcomes. International Journal of Pharmaceutics, 653, p.123862.

https://www.greaterbirminghamchambers.com/resource/university-wins-major-funding-for-3d-bioprinter-to-enable-new-research-into-how-the-body-works.html

Candidates should have been awarded, or expect to achieve, EITHER:

a] a First or Upper Second Class award in their Undergraduate Degree (Bachelors or UG Masters) from a UK institution, in a subject judged by Aston to be relevant to the proposed research.

Alternativley

b] a Merit (or above)* in a Postgraduate Masters degree in a relevant subject AND an Undergraduate Degree (Bachelors or UG Masters), both from UK institutions.

*where appropriate.

Qualifications from overseas institutions will be also considered but performance must be equivalent to that described above, and the University reserves the right to ascertain this equivalence according to its own criteria.

Financial Support

This project covers the Home tuition fees. Candidates who do not have Home status will be responsible for the difference in tuition fees. Currently, the difference between ‘Home’ and the ‘Overseas’ tuition fees is £17,712 for 2026/7.  

Overseas Applicants

Overseas applicants may apply for this studentship but will need to pay the difference between the ‘Home’ and the ‘Overseas’ tuition fees. Currently, the difference between ‘Home’ and the ‘Overseas’ tuition fees is £17,712 for 2026/7. As part of the application, you will be required to confirm that you will provide this additional funding. Please indicate this on the application form in the funding section.
 

Apply through our PhD application form.

When applying:

• For University College, please select Health Sciences
• For Degree Programme, please select Research Health Sciences (including Optometry, Pharmacy, and Psychology Research Areas) and your preferred entry date.

The supervisor can be contacted at c.russell6@aston.ac.uk.  When applying, please upload copies of your discussions with the supervisor as confirmation.

Overseas Applicants

Overseas applicants may apply for this studentship but will need to pay the difference between the ‘Home’ and the ‘Overseas’ tuition fees. Currently the difference between ‘Home’ and the ‘Overseas’ tuition fees is £17,712 for 2026/7. As part of the application, you will be required to confirm that you will provide this additional funding. Please indicate this on the application form in the funding section. This project has associated consumables costs which should be discussed with the supervisor in the first instance and before applying. The supervisor can be contacted at c.russell6@aston.ac.uk. When applying, please upload copies of your discussions with the supervisor as confirmation.

Apply now

If you require further information about the application process please contact the Postgraduate Admissions team at pgr_admissions@aston.ac.uk

Supervisor: Dr Craig Russell

Associate Supervisor: Professor Afzal Mohammed

Contact information

For formal enquiries about this project contact: c.russell6@aston.ac.uk

PhD programmes are for those who are seeking to develop greater in-depth knowledge in a specific area. Completing this level of study is about making an original contribution to knowledge, making new discoveries and developing lifelong skills. 

Studying a PhD is great route into academia and industries that are centred on research and innovation. Areas with a demand for very high level and specialised research skills often demand PhDs.

In addition to this specialist knowledge, PhD education will help you to develop a set of valuable transferrable skills. The very nature of studying an intensive research degree will enable you to become a team player, develop problem-solving skills, analytical thinking, and advanced presentation and communication skills.