A microneedle (MN) array is a novel biomedical device adopted in medical applications to pierce through the stratum corneum while targeting the viable epidermis and dermis layers of the skin. Owing to their micron-scale dimensions, MNs can minimize stimulations of the sensory nerve fibers in the dermis layer. For medical applications, such as wound healing, biosensing, and drug delivery, the structure of MNs significantly influences their mechanical properties. Among the various microfabrication methods for MNs, fused deposition modeling (FDM), a commercial 3D printing method, shows potential in terms of the biocompatibility of the printed material (polylactic acid (PLA)) and preprogrammable arbitrary shapes. Owing to the current limitations of FDM printer resolution, conventional micron-scale MN structures cannot be fabricated without a post-fabrication process. Hydrolysis in an alkaline solution is a feasible approach for reducing the size of PLA needles printed via FDM. Moreover, weak bonding between PLA layers during additive manufacturing triggers the detachment of PLA needles before etching to the expected sizes. Furthermore, various parameters for the fabrication of PLA MNs with FDM have yet to be sufficiently optimized. In this study, the thermal parameters of the FDM printing process, including the nozzle and printing stage temperatures, were investigated to bolster the interfacial bonding between PLA layers. Reinforced bonding was demonstrated to address the detachment challenges faced by PLA MNs during the chemical etching process. Furthermore, chemical etching parameters, including the etchant concentration, environmental temperature, and stirring speed of the etchant, were studied to determine the optimal etching ratio. To develop a universal methodology for the batch fabrication of biodegradable MNs, this study is expected to optimize the conditions of the FDM-based fabrication process. Additive manufacturing was employed to produce MNs with preprogrammed structures. Inclined MNs were successfully fabricated by FDM printing with chemical etching. This geometrical structure can be adopted to enhance adhesion to the skin layer. Our study provides a useful method for fabricating MN structures for various biomedical applications.

In medical ultrasound imaging, lateral resolution is limited when using a fixed transmit focusing. Various synthetic aperture (SA) techniques, in which two-way dynamic focusing is enabled by utilizing prebeamformed radio-frequency (RF) data have been proposed for improving the spatial resolution. However, SA methods were not extensively evaluated in terms of their clinical performance. In this paper, a phantom and an in vivo evaluation of the SA method with bidirectional pixel-based focusing (BiPBF) is presented in comparison with the conventional beamforming. The performance of the proposed SA-BiPBF was assessed with a blind study and the established breast imaging-reporting and data system (BI-RADS), in addition to measuring contrast-to-noise ratio (CNR) and signal-to-noise ratio (SNR). Prebeamformed RF data were acquired from a tissue mimicking phantom (Model 040, CIRS Inc., Norfolk, VA, USA) and from patients with breast lesions by using a commercial ultrasound scanning system with a linear array transducer equipped with a research package and parallel data acquisition system (SonixTouch, SonixDAQ, and L14-5/38, Ultrasonix Corp., Canada). In phantom and in vivo experiments, a default setting of a breast preset was applied (e.g., the center frequency of 10 MHz and acoustic output of MI = 0.66). In phantom experiment, the SA-BiPBF method showed higher CNR and SNR values compared to the conventional method (3.4 and 23.9 dB versus 3.1 and 15.8 dB, respectively). In addition, the lateral resolution and penetration depth were increased by 95.4% and 40.3%, respectively. Consistent with the phantom experiment, in the in vivo experiment with ten patients, the CNR value for the SA method was 3.3 ± 0.5 compared to 2.8 ± 0.8 for the conventional method. Similarly, the SNR values with the SA-BiPBF and conventional methods were 34.0 ± 3.6 and 27.2 ± 3.4 dB, respectively. From the experiments, it was shown in side-by-side comparisons that the image quality of the SA-BiPBF method was considerably improved in both phantom and in vivo breast images. However, the SA-BiPBF image showed different features compared to the conventional one in the in vivo experiments. These features are resulting from the increased image quality of the SA-BiPBF method but are not always perceived as improvements by the radiologists.