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2006 1:39pm

Stratum Corneum Bypassed

18 or Removed
James C. Birchall

CONTENTS

18.1 Introduction ............................................................................................................. 337

18.2 The Skin as a Barrier to Gene Delivery ................................................................... 338
18.3 Methods for Enhancing Drug Delivery to Skin ....................................................... 338
18.3.1 Microfabricated Microneedle Arrays .......................................................... 339
18.3.1.1 Silicon Microneedle Structures .................................................... 340
18.3.1.2 Microneedle Structures Prepared from Other Materials ............. 340
18.3.1.3 Hollow Microneedles ................................................................... 342
18.3.1.4 Microneedle Application Forces.................................................. 343
18.3.1.5 Medical Applications for the Use of Microneedles ..................... 343
18.3.2 Other Methods for Disrupting Stratum Corneum ...................................... 346
18.3.2.1 Tape Stripping ............................................................................. 346
18.3.2.2 Laser Methods ............................................................................. 346
18.3.2.3 Abrasive Methods........................................................................ 346
18.3.2.4 Puncturing Methods .................................................................... 347
18.3.2.5 Ballistic Methods ......................................................................... 348
18.4 Conclusion ............................................................................................................... 348
Acknowledgments .............................................................................................................. 348
References .......................................................................................................................... 349

18.1 INTRODUCTION
The skin represents an attractive gateway for the localized and systemic delivery of therapeut-
ically active molecules due to its ready accessibility, avoidance of gastrointestinal degradation
and liver inactivation, monitoring capability and potential for improved patient compliance.
The ability to deliver therapeutic quantities of medicaments to and through the skin, however,
is dependent on the physicochemical properties of the candidate drug and the significant barrier
properties of the target tissue. After all, a primary function of the skin is to restrict the ingress of
external matter through physical blockade and immune surveillance. Whereas traditional
transdermal delivery techniques use formulation strategies to promote the transport of small
molecules through the stratum corneum, a growing number of delivery techniques that aim to
bypass or disrupt the skin barrier have been developed. Such strategies, including the use of
chemical enhancers [1], iontophoresis [2], electroporation [3], and sonophoresis [4] may sup-
plement traditional transdermal delivery strategies or provide a means of delivery for new drug
candidates, including macromolecules. Despite these advances, and a few exceptions, it could
be argued that effective transdermal delivery is still generally restricted to a small number of low
molecular weight, weakly lipophilic, and potent therapeutic molecules. Increasing emphasis on

337
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338 Enhancement in Drug Delivery

the administration of biotechnology-derived macromolecular, particulate- and DNA-based

medicines requires the development of further delivery strategies and devices that circumnavi-
gate the stratum corneum barrier to promote delivery of a wide range of therapeutics to the
underlying epidermis, dermis, and possibly the systemic circulation. Clearly, as the requirement
for the efficient delivery of larger molecules and nanoparticles increases more radical methods
of disrupting skin barrier function are required.

18.2 THE SKIN AS A BARRIER TO GENE DELIVERY

The primary role of the skin is to serve as a physical and immunological barrier to the
invasion of foreign material. Simply, the skin can be considered as a structure composing
three distinct layers, the epidermis, dermis, and hypodermis, and hosting a number of adnexal
features such as hair follicles, sebaceous glands, and sweat glands. In humans the uppermost
layer of the skin, the epidermis, ranges from 50 to 150 mm in thickness. The external surface of
the epidermis is comprised of flattened nonviable cells that have lost their nuclei following
differentiation from the inner to the outer layer of the epidermis. This layer is termed the
stratum corneum, approximately 15–20 mm in thickness, and its physical properties make it
the principal barrier to the penetration and permeation of substances through the skin. The
remainder of the epidermis is a progressively differentiated stratified epithelium. The range of
cell types found in the epidermis includes keratinocytes, melanocytes, Langerhans cells, and
Merkel cells. The differentiated keratinocytes arise from a pool of transient amplifying cells
located at the basal layer of the epidermis, which in turn are derived from epidermal stem
cells. Although stem cells can be isolated from the epidermis in vitro and typically express
certain cell surface markers, these cells are presently impractical to selectively target in vivo [5].
The dermis is a connective medium underlying the epidermis, and acts as a protective layer
against injuries and deformation and also maintains a role in thermal regulation. The dermis
contains collagen, elastin, blood and lymphatic vessels, nervous elements, and scattered cells
including fibroblasts, mast cells, macrophages, and lymphocytes. The hypodermis, the layer
beneath the dermis, is composed of subcutaneous fat and blood vessels. Its main role is to
maintain skin mobility, and to supply energy and insulate the body.
It has been firmly established that the structural basis of the skin permeability barrier in
mammals is the stratum corneum [6], as once a compound crosses this barrier it can diffuse
rapidly through deeper tissue and be taken up by the underlying capillaries. Therefore to
deliver therapeutic compounds to the epidermis, dermis, or systemic circulation, delivery
strategies must overcome the physical barrier afforded by the nature of the tightly packed
dead cells of the stratum corneum. Conventional transdermal formulation strategies aim to
enhance the delivery of small therapeutic molecules, less than 500 molecular weight in size,
across the stratum corneum through the paracellular, transcellular, or intracellular routes.
However, to deliver macromolecular products such as genes and proteins, more innovative
and drastic methods of drug delivery are required.

18.3 METHODS FOR ENHANCING DRUG DELIVERY TO SKIN

The simplest, although crudest, method for bypassing the stratum corneum barrier is to
administer medicines through direct injection. For over 150 years this technique of drug
delivery, initially devised as a method for delivering opiates [7], has been used to administer
medicaments to compartments of skin, muscle, and the systemic circulation. Whereas hypo-
dermic injection will remain a routine drug delivery method due to its significant drug-loading
capability and well-defined pharmacokinetics, alternative technologies are being developed to
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Stratum Corneum Bypassed or Removed 339

bypass the stratum corneum in a more sophisticated manner with an associated reduction in
pain and diminished risk of phlebitis, hematoma, and thrombosis. Although modern fabri-
cation methods are now used to manufacture individual needles, this chapter will focus on the
innovative new technologies at the forefront of intra- and transdermal drug delivery.

18.3.1 MICROFABRICATED MICRONEEDLE ARRAYS

In recent years, a particularly exciting alternative to conventional needle and syringe injection
has been developed. Microneedle approaches are designed to circumnavigate the primary skin
barrier without impinging on the underlying pain receptors and blood vessels (Figure 18.1).
Microneedle manufacturers employ microelectromechanical systems (MEMS) technology,
regularly utilized in the semiconductor and microelectronics industry, to create arrays of
needles from a base material. Commonly the microneedles are fabricated from silicon and in
these cases the microneedles are prepared using well-defined etching techniques [8]. Although
the practical application of this technique has only been demonstrated for the first time within
the past 10 years, the original concept for these delivery systems was described nearly 30
years ago [9].
Microneedles, so termed as they commonly range from 100 to 1000 mm in length, are
designed to perforate the stratum corneum thus providing a direct and controlled route of
access to the underlying tissue layers. When inserted into the skin, microneedles create
microscopic punctures through the stratum corneum and into the viable epidermis. The
length of the microneedle is controlled to ensure that the depth of penetration does not

(a)
Stratum corneum
Epidermis

Dermis
Pain receptors
Blood vessels

(b) (c)

FIGURE 18.1 Schematic representation of the concept for microneedle-assisted delivery. (a) The micro-
needles penetrate the stratum corneum, to facilitate access of molecules to the viable epidermis, without
impacting on the underlying nerve endings and blood vessels; (b) when removed the microneedles have
created conduits for drug delivery; (c) hollow microneedles allow direct injection of the formulation.
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340 Enhancement in Drug Delivery

impinge on the nerve fibers and blood vessels that reside primarily in the dermal layer. The
micron-sized channels can therefore facilitate the delivery of both small and large molecular
weight therapeutics into skin without causing pain or bleeding at the site of application [10].
The advantages of using microneedles include: (a) direct and controlled delivery of the
medicament, (b) rapid exposure of large surface areas of epidermis to the delivery agents
(microneedle arrays can contain over 1000 microneedles), (c) effortless, convenient, and
painless delivery for the patient, (d) ability to manipulate the drug formulation, e.g., solution,
suspension, emulsion, dry powder, and gel, (e) enhancing the impact of concomitant delivery
methods such as transdermal patches, and (f) a minimally invasive methodology suited to
patient self-administration without the need for medical supervision. A particularly import-
ant advantage lies in the ability to adapt the materials, types of structure, and dimensions of
the needle to facilitate the delivery of macromolecules, nanoparticles, and vaccines [11,12].

18.3.1.1 Silicon Microneedle Structures

In collaboration with The Cardiff School of Engineering and Tyndall National Institute,
Cork, our laboratories have characterized and exploited microneedles prepared using dry-
and wet-etching methodologies.
At the start of the dry-etch microfabrication process a silicon wafer is coated with a positive
photosensitive material. A standard high-resolution chromium-plated lithographic mask
bearing the appropriate dot array pattern is used during the UV light exposure step to
produce a photoresist etch mask. The surface is subsequently etched using a reactive blend
of fluorinated and oxygen gases, with those regions protected by the photoresist mask
resisting the etching process and leading to the formation of microneedles. The result,
following removal of the photoresist, is an array of microneedles of approximately 150 mm
in length. Figure 18.2a shows scanning electron micrographs of an array of cylindrical
microneedles prepared by using this technique [12].
In an alternative preparation method, microneedles have also been prepared through wet-
etching technologies using potassium hydroxide, KOH, at elevated temperatures. Solid
microneedles are formed through a number of process steps involving a mask layout lithog-
raphy step, crystal alignment, low-pressure chemical vapor deposition (LPCVD), plasma
etching to create the mask on the wafer, wet etching using KOH, and mask release by cleaning
procedures [13]. Figure 18.2b shows scanning electron micrographs of an array of pyramidal
microneedles prepared by using this technique.
If skin is placed in a water bath under controlled conditions [14] the primary barrier to
transdermal delivery, the epidermal membrane comprising the stratum corneum and viable
epidermis, can be readily removed and used to analyze the penetration and diffusion of
materials. Figure 18.3a and Figure 18.3b show the appearance of human breast epidermal
membrane, with epidermis facing uppermost, following application of the cylindrical dry-etch
and pyramidal wet-etch silicon microneedles, respectively. In each case the microneedles are
clearly shown to pierce the stratum corneum and viable epidermis to facilitate controlled
access of molecules to the target region of skin.

18.3.1.2 Microneedle Structures Prepared from Other Materials

Professor Mark Prausnitz and his research colleagues based at the Georgia Institute of
Technology have been at the forefront of developments in the microfabrication processes
used to create microneedle arrays from a range of base materials. The methods employed
generally involve one or two fabrication steps or a single molding stage and use technologies
that are readily scalable for industrial mass production [15]. As a result, in addition to using
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Stratum Corneum Bypassed or Removed 341

(a) (b)

Acc V Spot Magn Det WD Exp 1mm

20.0 kV 3.0 50x SE 10.8 3 Run2601­W8N

(c) (d)

Acc V Spot Magn Det WD Exp 100∝m

Acc V Spot Magn Det WD Exp 100∝m
20.0 kV 3.0 500x SE 11.2 3 Run2652­W18N
20.0 kV 3.0 500x SE 10.7 3 Run2601­W8N

FIGURE 18.2 Scanning electron micrographs of silicon microneedles. (a) Silicon microneedles micro-
fabricated using a modified form of the BOSCH deep reactive ion etching process. The microfabrication
process was accomplished at CCLRC Rutherford Appleton Laboratory (Chilton, Didcot, Oxon, UK).
The wafer was prepared at the Cardiff School of Engineering, Cardiff University, UK. Bar ¼ 100 mm;
(b–d) platinum-coated silicon microneedles prepared using a wet-etch microfabrication process per-
formed at the Tyndall National Institute, Cork, Ireland. Bar ¼ 1 mm (b), 100 mm (c,d).

silicon, a brittle material that regularly fractures on microneedle application, as the primary
structural component, microneedles have been fashioned from metal, polymer, and glass.
Metal microneedles were manufactured by electrodeposition of metal onto a polymer
or silicon micromold. Glass microneedles were created by conventional drawn-glass
micropipette techniques. Polymer microneedles were fabricated by melting polyglycolic
acid, polylactic acid, or polylactic-co-glycolic acid into polydimethylsiloxane (PDMS) micro-
molds [16] with these structures demonstrating up to three orders of magnitude increase in the

(a) (b)

FIGURE 18.3 Scanning electron micrographs of epidermal membrane treated with dry-etch and wet-
etch silicon microneedles. The epidermal membrane, consisting of stratum corneum and viable epider-
mis, was obtained by heat separation of full-thickness human breast skin. The tissue was immersed in
distilled water preheated to 608C for 60 s and the upper layers carefully peeled off from the dermal layer
using tweezers. Epidermal membranes were treated with microneedles for 30 s at an approximate
pressure of 2 kg=cm . (a) Dry-etch microneedle-treated epidermal membrane. Bar
2
¼ 200 mm; (b) wet-
etch microneedle-treated epidermal membrane. Bar ¼ 500 mm.
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342 Enhancement in Drug Delivery

permeability of human cadaver skin to a low molecular weight trace molecule, calcein, and a
macromolecular protein, bovine serum albumin.
The ability to prepare microneedles from alternative material substrates confers important
advantages to the industrial exploitation of the technique. Whereas silicon microneedles are
generally fabricated in dedicated, and costly, clean room facilities, polymer and metal micro-
devices would be less expensive to mass produce as the raw materials are more available at a
reduced cost and the single-step molding techniques do not require specialist amenities. From
a clinical perspective many metals and polymers, as opposed to silicon, have established
biomaterial safety profiles and are more robust and less likely to shear upon skin application
and removal. A further advantage, specific to the use of polymeric material, relates to the
ability to manipulate the recipe to formulate biodegradable microneedles capable of either
in situ biological degradation following application or environmental degradation following
termination of use. Recently, potentially multifunctional polymeric microneedles comprising
a multilayer structure have also been prepared by Kuo and Chou [17].
A recent materials innovation in this field describes a method for coating microporous
calcium phosphate onto stainless steel acupuncture needles [18]. The incorporation of treha-
lose into the porous coating acted as a model fast-dissolving reservoir for the potential
loading and stabilizing of protein and DNA vaccines. The coated needles were shown to
remain intact following contravention of the stratum corneum and allow access of the coated
material to the viable epidermis. Importantly, no evidence of skin reaction, bleeding, or
infection was observed.

18.3.1.3 Hollow Microneedles

Whereas solid microneedle arrays present the opportunity to create conduits through the
restrictive skin barrier layer, the application of the formulation into the channel through dry-
coating the microneedle array or coadministration of a solution, suspension, emulsion, or gel
containing the medicament generally relies on passive delivery mechanisms. The capacity to
microfabricate hollow microneedles, however, allows a controlled quantity of the medicament
to be actively delivered from the tip of the inserted microneedle at a defined rate. In addition,
hollow microneedles provide the opportunity to not only deliver substances but also to
withdraw material from the skin for analysis, monitoring, and responsive purposes.
McAllister et al. [19] reported the fabrication of hollow tapered microneedles and micro-
tubes using a combination of dry-etching processes, micromolding and selective electroplating
or by direct micromolding. Another reported method for preparing hollow microneedles
utilizes a combination of silicon microfabrication and copper electroplating technologies
[20]. As the layer of copper on the square-pyramidal microneedles is designed to be thicker
at the base than at the tip, structural stability is provided to the structure. One significant
drawback, however, lies in the acknowledgment that copper can cause skin sensitization
reactions and is prone to oxidation. As an alternative, tapered hollow nickel microneedles
have also been prepared by a rapid, simple, and relatively inexpensive method [21].
A recent study used hollow microneedles with the following dimensions: 20–100 mm in
diameter and 100–150 mm in length to deliver insulin through skin [22]. In vivo tests in diabetic
animals, however, were unable to demonstrate any functional delivery of insulin through the
hollow microneedles. It is therefore essential that the engineering processes evolve to ensure
that both microneedle length and tip sharpness are optimized for systemic drug delivery to be
seen in vivo.
The preparation of hollow microneedles affords the ability to combine the microneedle
array with microfluidic channels to facilitate active insertion of the medicament into various
layers of skin. This serves to increase the volume of medicament entering the skin, as opposed
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Stratum Corneum Bypassed or Removed 343

to passive diffusion of liquid into a microchannel created using a solid microneedle, and
provides the opportunity to pulse or continuously replenish the medicament over a period of
time. The extensive work of Zahn et al. [23] has shown that continuous pumping of fluid
through microneedles can be achieved for more than 6 h.

18.3.1.4 Microneedle Application Forces

Although modern engineering techniques have fashioned a range of microneedle morpholo-
gies with potential utility for delivering drugs through the skin, it has become apparent that
certain designs are more capable of easy insertion into, and removal from, the skin without
causing damage to the microneedle structure. For instance, if the microneedles are not sharp
enough, or are insufficiently spaced, then the skin will resist penetration due to excessive
distribution of the imposed application force; i.e. a bed of nails effect. Conversely if the
needles are too long or too widely distributed on the array the tip of the needle may not have
sufficient rigidity and may break off on insertion. Wang et al. [24] specifically fabricated
single hollow glass microneedles at a range of tip diameters and bevel angles to determine
their ability to puncture human cadaver and in vivo rat skin. The authors found that the
volume of liquid injection and interstitial fluid extraction depend on the microneedle geom-
etry, with the larger needle tips facilitating more liquid injection and extraction. The same
research group has also theoretically modeled and experimentally quantified two critical
determinants, i.e., the force required to insert microneedles into skin and the force needles
can withstand before fracturing [25]. The authors found that microneedle insertion force
increases as a linear function of needle tip cross-sectional area with a measured insertion
force of 0.1–3 N, making microneedle penetration into skin readily achievable by hand. The
force required to fracture the microneedles increased with increasing wall thickness, micro-
needle angle, and tip radius and encouraging this force was always in excess of that required
for adequate insertion of the microneedle. A further study proposed that a microneedle length
of 600 mm was optimal when a combination of factors such as microneedle strength and
robustness, minimal insertion pain, and skin damage are taken into consideration [26].
An interesting approach to assist microneedle insertion involves the use of vibrations to
drive the needles into skin. Clearly, this has firm theoretical basis in nature as mosquitoes are
able to pierce human skin using a vibratory cutting action at a frequency of 200–400 Hz.
Coupling a vibratory actuator to hollow microhypodermic needles leads to more than 70%
reduction in the force required to insert the needles into excised animal skin [27]. Ultrasound
can be used to reduce the deformation of the skin on penetration and potentially provides a
biological lubricating layer to assist microneedle insertion. The penetration force of micro-
needles into silicon rubber and vegetable skin simulates has shown to be reduced significantly
when bonded to piezoelectric actuators [28].
From a skin application perspective it appears logical that rolling the microneedles onto the
skin surface, in a manner analogous to printing presses, would result in greater penetration
than direct application from above. Although the DermaRoller was developed for maximiz-
ing the penetration of cosmetically active materials, the cylindrical rolling design, comprising
an array of metallic microneedles of varying lengths, should be further investigated for the
delivery of other therapeutics [29].

18.3.1.5 Medical Applications for the Use of Microneedles

Microneedle arrays were originally designed to mediate the transdermal delivery of low
molecular weight drugs or reporter molecules to the systemic circulation, resulting in the
enhanced penetration of calcein [8], trypan blue [30], and methyl nicotinate [31]. In our
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344 Enhancement in Drug Delivery

(a) (b)

FIGURE 18.4 Methylene blue staining of dry-etch (a) and wet-etch (b) microneedle-treated human skin.
Disruptions within the stratum corneum indicate microneedle penetration efficiency.

laboratories we routinely validate the creation of functional microchannels using methylene

blue as a visual reporter molecule (Figure 18.4). Whereas microneedles are ideally suited for
this purpose, the dimensions of the microchannels created within skin expand the applicabil-
ity of this approach to the delivery of macromolecular therapeutics, such as proteins, nano-
particles, and nucleic acids.
The in vivo pharmacodynamic response to a therapeutic protein delivered through micro-
needles was recently demonstrated in a diabetic hairless rat model [32]. Insulin was selected as
a nonpermeable clinically relevant protein with current drug administration issues, i.e., the
requirement for regular painful and inconvenient injections. Laser ablation of a stainless
steel sheet and subsequent bending of the planar microneedle shape was used to produce
solid metallic microprojections of 1000 mm length. Coadministration of insulin solution
and microneedles, followed by microneedle removal, enhanced the transdermal delivery of
insulin and mediated an 80% reduction in blood glucose. The authors concluded that micro-
needles are capable of delivering physiologically relevant amounts of insulin with rapid
pharmacodynamic action and appear to have broad applicability for a range of therapeutic
macromolecules.
Several companies are currently developing microneedles for sustained drug delivery.
Nanopass Technologies Ltd. (Haifa, Israel) has developed the Nanopump for the prolonged
delivery of insulin through robust-engineered micropyramids [11]. Despite the clear advan-
tages of this approach, as opposed to conventional invasive insulin administration devices,
further studies are required to optimize the rate and quantity of delivery. BD Medical Systems
(Franklin Lakes, NJ, USA) have developed a prefilled, disposable device, MicroInfusor, that
is activated by the patient to enable relatively large volume administration without dermal
back pressure.
Currently microneedle technology is exploited to deliver plasmid DNA (pDNA) into, and
study the subsequent gene expression within, the viable epidermis [12,33]. The specific and
efficient immune processing properties of skin have resulted in significant interest in the
development of genetic vaccines [34–36] that can capitalize on the innate ability of Langer-
hans cells, powerful antigen-presenting cells (APCs) residing within the viable epidermis, to
proficiently present antigen to stimulate an antigen-specific T-cell immune response. Clearly,
microneedles represent a practicable method for targeting these cells in skin. In addition, the
ability of microneedle arrays to penetrate cells for the intracellular delivery of DNA has also
been shown to be possible in an in vitro environment in plant cells [37] and nematodes [38],
with about 8% of the total progeny tested expressing the foreign gene in the latter case.
In our laboratories we have investigated microneedles for their potential to facilitate gene
delivery to the viable epidermis of skin. Our studies have confirmed that the delivery of naked
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Stratum Corneum Bypassed or Removed 345

pDNA, i.e., pDNA formulated without additional complexing or targeting elements, through
microneedle-facilitated microchannels results in measurable levels of reporter gene expression
in excised human skin. Figure 18.5 shows typical results from skin transfection experiments.
En face imaging, following delivery of pCMVb reporter gene and staining with X-Gal, shows
microchannels stained positive for reporter gene expression (Figure 18.5a and Figure 18.5b).
Microchannel counterstaining with nuclear fast red shows that only a minority of micro-
channels were shown to be positive for gene expression (Figure 18.5a). These studies therefore
validate the skin explant organ culture conditions in maintaining the cellular viability of
excised skin and provide a realistic assessment of the current efficiency of the microneedle
technique for facilitating gene transfer. Photomicrographs showing the high level of reporter
gene expression in viable epidermal cells are presented in Figure 18.5c and Figure 18.5d.
Further studies are currently utilizing optimized microneedle devices to facilitate more
reproducible cutaneous gene delivery and explore additional factors that influence gene
expression in epidermal cells.
BD Technologies (Research Triangle Park, NC, USA) have used microfabricated silicon
microneedles, in their case termed microenhancer arrays (MEAs), to deliver genetic vaccines
to skin [39]. The application protocol involved applying a solution of DNA to the surface of
mouse skin and laterally scraping the microneedle array across the skin. The authors report a
2800-fold increase in reporter gene activity in comparison with conventional topical applica-
tion of controls and a more proficient and reproducible immune response in comparison with
needle injection. Encouragingly, lateral application of the MEA to human subjects confirmed
that the devices can breach the skin barrier with negligible to minimal skin irritation, no
damage to the microneedle array, and no reported incidence of infection.

(a) (b)

(c) (d)

FIGURE 18.5 Light photomicrographs of microneedle-treated human skin stained for b-galactosidase
expression. (a) En face stereomicroscopy of dry-etch microneedle-treated skin with nuclear fast red
counterstaining; (b) en face stereomicroscopy of wet-etch microneedle-treated skin; (c) hematoxylin and
eosin stained 12 mm cryosection of dry-etch microneedle-treated skin. Bar ¼ 100 mm; (d) hematoxylin
and eosin stained 12 mm cryosection of wet-etch microneedle-treated skin. Bar ¼ 100 mm.
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346 Enhancement in Drug Delivery

A further advantage in utilizing the microneedle approach for vaccination and for the
delivery of proteins, peptides, and nucleic acids lies in the possibility of adjusting formulation
to meet stability and cost requirements. 3M Drug Delivery Systems (St Paul, MN, USA) and
ALZA Corporation (Mountain View, CA, USA) have developed methods to dry coat
microneedles with vaccine or drug to eliminate common pharmaceutical and resource con-
cerns over poor drug aqueous stability and cold-chain vaccine storage [11]. The future
application of these technologies is likely to have a significant future role to play in mass
immunization programs. ALZA have developed a microprojection patch (Macroflux) for the
controlled delivery of medicaments. Macroflux comprises a stainless steel or titanium micro-
projection array, fabricated from metallic foil, which is used to create superficial pathways in
skin and facilitate delivery of medicaments. This drug delivery system has been used to deliver
the peptide hormone desmopressin [40] and protein antigens [41] dry coated onto the projec-
tions, or in conjunction with iontophoresis for the administration of therapeutically relevant
quantities of oligonucleotides [42].

18.3.2 OTHER METHODS FOR DISRUPTING STRATUM CORNEUM

Whereas microneedles are designed to pierce through the outer layers of skin, the controlled
destruction or adhesive removal of the stratum corneum represent alternative methods for
overcoming the penetrative barrier to cutaneous drug delivery.

18.3.2.1 Tape Stripping

Since the early 1960s it has been recognized that the principal skin barrier can be removed
using adhesive tape [43]. Tape stripping is now a routine analytical method for determining
epidermal physiology and the permeation and dermatopharmacokinetics of substances within
skin. The variability in the area and depth of stratum corneum removed by tape stripping is
not only dependent on the type of tape used and the skin characteristics of the individual
subject but also on the anatomical site, application pressure, duration of time in contact with
the skin, and method of removal [44,45]. These factors, combined with the associated safety
concerns of removing the skin barrier, confirm that tape stripping, although useful as a
scientific tool, will never be appropriate for clinical exploitation.

18.3.2.2 Laser Methods

More controlled ablation and removal of the stratum corneum has been achieved using laser
methods. A variety of lasers including the ruby laser [46], carbon dioxide laser [46], argon–
fluoride laser [47], and erbium:YAG (yttrium–aluminum–garnet) laser [46,48–50] have been
employed to enhance the percutaneous transport of molecules. Whereas physical disruption
of skin barrier was not evident following application of the ruby laser [46], for the other lasers
partial removal of stratum corneum (approximately 12% of diffusional area [49]), the ap-
pearance of granular structures on the stratum corneum surface and localized thermal effects
led to the significant enhancement in skin permeation of 5-fluorouracil [46], 5-aminolaevulinic
acid [48], dextran [47], hydrocortisone, gamma-interferon [49], indomethacin, and nalbuphine
[50]. Furthermore the recovery of barrier function and epidermal thickness was demonstrable
within 5 days following application of the most exploited laser (erbium:YAG; [50]).

18.3.2.3 Abrasive Methods

The method of microdermabrasion was developed as a technique to cosmetically treat
photoaging, hyperpigmentation, acne, scars, and stretch marks [51,52]. The procedure
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Stratum Corneum Bypassed or Removed 347

involves trajecting inert sharp particles, e.g., aluminum oxide crystals or other abrasive sub-
stances, onto the skin and subsequent removal of the crystals and abraded material. Using this
technique skin barrier function is transiently compromised with restoration within 24 h [53].
This method has been employed to enhance the topical permeation of vitamin C, 20-fold
increases in flux and skin deposition are reported when compared with intact skin [54], and
5-aminolaevulinic acid, up to 15-fold increase in skin permeation [48]. Interestingly in this latter
example, the permeation enhancement effect was significantly augmented by synergistic use of
electroporation or iontophoresis. O Herndon et al. [55] described the use of a gas-entrained
stream of 10–70 mm aluminum oxide particulates for the formation of microconduits for
transdermal delivery and sample acquisition [55]. The 50–200 mm depth channels formed by
microscission permitted rapid functional anesthesia following topical application of lidocaine
and allowed for the removal of blood glucose for monitoring purposes. An alternative method
for enhancing skin permeability uses standardized skin minierosion whereby an epidermal bleb
is created by suction to facilitate diffusion of analgesia for postoperative pain relief [56].

18.3.2.4 Puncturing Methods

Ciernik et al. [57] reported the installation and expression of a solution of naked DNA in mice
using high-frequency puncturing of skin with oscillating needles (1 cm length and 250 mm
diameter). The authors demonstrated that this tattooing technique led to the enhanced
expression of reporter gene compared with both direct subepidermal injection and
topical application. This method was also used to demonstrate the induction of cytotoxic
T-lymphocytes using a peptide oligonucleotide. Eriksson et al. [58] used a similar technique,
termed microseeding, to deliver expression plasmids to intact porcine skin and partial thick-
ness wounds and confirmed that the procedure proved more efficient than direct injection and
particle-mediated gene transfer.
TransPharma Medical has developed an innovative technology (RF-Microchannelse) to
create transient microchannel conduits in skin for direct and controlled access of molecules
across the stratum corneum for diffusion to the underlying viable epidermis and dermis
[59,60]. The technology comprises an intimately spaced array of microelectrodes, which are
placed against the surface of skin to individually conduct an applied alternating electrical
current at radio frequency (RF). During the application of RF energy, a frequency alternating
current moves from the tip of the electrode into the surrounding tissue, creating localized
heating and subsequent cell ablation. Microscopic studies have shown that the RF micro-
channels generated reside in the outer layer of skin and do not impact on the underlying blood
vessels and nerve endings, thereby resulting in minimal skin trauma, bleeding, and neural
sensations [59]. This technology has shown utility in the transdermal delivery of polar
hydrophilic molecules including granisetron hydrochloride and diclofenac sodium [59] and
has recently shown further applicability to high molecular weight medicaments [60].
The creation of physical openings through the stratum corneum can also be facilitated by
applying an array of tiny-resistive elements to the skin surface and transmitting a short
electric current. Localized resistive heating effects vaporize the cells of the stratum corneum
leaving a microscopic hole, and are termed as micropore [61]. As natural desquamation
processes repair the micropore, a transient window is provided for cutaneous drug delivery.
Reporter gene expression using an adenoviral vector has been increased 100-fold, when
compared with intact skin, using this method with similar increases in cellular and humoral
immune responses following topical administration of adenovirus vaccine.
Further advances in skin resurfacing technologies, such as the use of gas jets and
accelerated microdroplets (JetPeel [62]), may offer additional mechanisms for transporting
medicaments through the stratum corneum barrier.
 Elka Touitou / Enhancement in Drug Delivery 3203_C018 Final Proof page 348 3.10.2006 1:39pm

348 Enhancement in Drug Delivery

18.3.2.5 Ballistic Methods

The use of ballistic devices to propel materials through the stratum corneum and into the
underlying tissue has been widely reported as a method for enhancing the delivery of
anesthetics and biotechnology-derived drugs, such as proteins, peptides, vaccines, and nucleic
acids, through the skin. The Powderject system accelerates pharmaceuticals in particle form
and has shown utility for the delivery of conventional and genetic vaccines. Recent studies
have identified optimum particle parameters and acceleration velocity to target specific skin
layers and established sources of variability [63]. The commercially available Helios Gene
Gun (Bio-Rad Laboratories, Hercules, CA, USA) utilizes a helium cylinder to accelerate
ß

DNA-coated gold particles into target cells or tissues. The gold particles are typically around
1 mm in diameter and can penetrate through cell membranes, carrying the bound DNA,
typically 0.5–5 mg=mg gold, into the cell cytoplasm. Subsequent dissociation of the DNA
from the carrier particles allows the gene to be expressed [64]. Numerous studies have shown
the successful delivery and expression of genes using this method, with both reporter genes
and therapeutic plasmids having been transported to mammalian cells in culture [65],
oral mucosa [66], cornea [67], and animal skin [68–70]. Whereas expression of the transgene
is usually transient, lasting from a few days up to 4 weeks [71], Cheng et al. [68]
reported sustained luciferase activity in rat dermis one and a half years after in vivo particle
bombardment.

18.4 CONCLUSION
New technologies at the interface of engineering and biological sciences have provided the
drug delivery specialist with fresh opportunities for administering a range of therapeutics to
and through skin. The clinical exploitation of these technologies does not seem to be too
remote; however, there remain some limitations in these approaches, which necessitate further
investigation. It could be debated that creating channels, of any dimensions, in skin is
inherently dangerous and creates the opportunity for lasting skin damage and infection. Do
researchers in this area truly understand the kinetics and mechanisms of skin healing in
response to these assaults on skin integrity? Where a physical structure, such as a microneedle,
is used to penetrate the skin are any hyperproliferative, stress, or immune responses triggered?
As these devices are often designed to be used by patients in the absence of clinical interven-
tion is the hardware sufficiently simple to use in a safe and reproducible manner to create a
consistent number of channels at a reliable depth? As the stratum corneum acts as our
security blanket to infiltration by foreign bodies, are we wise in compromising it?
In my opinion these questions will be addressed, although it is clearly important that the
biological scientists work with the engineering scientists to ensure the development of these
technologies is treatment, disease, and patient focused rather than motivated by the tech-
nologies themselves.

ACKNOWLEDGMENTS
The significant contributions of Feriel Chabri, Marc Pearton, Sion Coulman, Ben Taunton,
Dr. Chris Allender, and Dr. Keith Brain are gratefully acknowledged. I am indebted to
Professor David Barrow, Tyrone Jones, and Kostas Bouris, Cardiff School of Engineering,
Cardiff University, and Dr. Anthony Morrissey and Nicolle Wilke, Tyndall National Institute,
Cork for their continued microfabrication support. I also thank Dr. Anthony Hann, Cardiff
School of Biosciences, for assistance with electron microscopy and Drs. Alexander Anstey,
Chris Gateley. and Helen Sweetland for clinical support.