Future of Vaccine Delivery, Contingent on Printer Technology

In the fight against COVID-19, vaccines have proven to be a critical tool in preventing severe illness and death. However, the worldwide demand for vaccines has highlighted the need for more efficient and scalable vaccine manufacturing and distribution systems. Recently, a team of MIT researchers published an article in Nature Biotechnology that introduces a novel approach to vaccine delivery: a microneedle vaccine printer that can produce thermostable COVID-19 mRNA vaccines.

The Challenge of Vaccine Manufacturing and Distribution

The COVID-19 pandemic has underscored the need for vaccines that can be manufactured and distributed quickly and efficiently. Traditional vaccine production methods, which rely on growing large quantities of live virus or bacteria, can be time-consuming, expensive, and prone to contamination. Moreover, the distribution of vaccines requires a cold chain system to keep the vaccines at a low temperature, making transportation and storage more complex and expensive.

Microneedle Patches for Vaccine Delivery

The goal of the MIT researchers was to create a tool that would enable the rapid production and distribution of vaccinations in the event of disease epidemics like the Ebola virus. They chose to use new patches containing hundreds of microneedles, roughly the size of a thumbnail, for vaccine administration. The patch releases the vaccine when it is put to the skin because the needle tips disintegrate beneath the skin. Many illnesses, including polio, measles, and rubella, are currently being treated with microneedle patches.

Vaccines On Demand

A printer that can instantly print vaccination patches was created by the researchers. The researchers chose to experiment with microneedle patches instead of creating conventional injectable vaccines because they had various benefits over conventional immunizations. These include being painless to administer, and easier to handle, distribute, and store. Anybody can apply the patches to the skin, negating the need for medical experts with the necessary training. Because the patches can be produced on demand, they are perfect for use in military bases, refugee camps, and other outlying locations.

Thermostable mRNA Vaccine Production

The necessity for a vaccination that is simple to administer, store, and transport was made clear by the COVID-19 pandemic. Traditional vaccines need to be refrigerated, which makes it difficult to store and deliver them in far-flung places or in developing nations. The scientists created a vaccination with lipid nanoparticle-encased RNA vaccine molecules. This ink is put into the microneedle molds, which are then vacuum-sucked to the bottom to ensure that the ink gets all the way to the needle tips. Molds require one or two days to dry after being filled. The patches may be kept at ambient temperatures for up to six months, according to the investigators, and a batch that was kept at 37 degrees Celsius for a month still preserved its effectiveness.

Comparable Immunogenicity

By administering two doses of the COVID-19 vaccination to mice four weeks apart, the researchers examined the COVID-19 vaccine’s effectiveness. They next evaluated the virus’s reaction to their antibodies. The scientists discovered that mice given the microneedle patch vaccination responded similarly to those given the conventional, intravenous RNA vaccine. This proves that the microneedle patch works just as well as conventional immunizations.

Wider Scope of Application

The researchers in the study likely developed a new method for producing RNA vaccines that can be adapted to produce other types of vaccines as well. This may involve modifying the mRNA sequence to code for different proteins, such as those found on the surface of other viruses or pathogens. Alternatively, the process may involve using different types of genetic material or vectors to deliver the vaccine to cells.

There are several advantages to being able to manufacture various vaccine kinds using the same production method. First, since the manufacturing process has already been established, it can cut down on the time and expense needed to develop new vaccines. Additionally, it can make vaccine production more adaptable and scalable, enabling producers to quickly switch to producing different vaccines in response to emerging pathogens or altering public health requirements.

Overall, the ability to adapt the process of producing RNA vaccines to produce other types of vaccines is a promising development that could have significant implications for the future of vaccine development and manufacturing.

Study DOI: 10.1038/s41587-023-01774-z

Engr. Dex Marco Tiu Guibelondo, BS Pharm, RPh, BS CpE

Editor-in-Chief, PharmaFEATURES