Injectable Microparticle Assembly

A breakthrough design for injectable microparticles was developed, published, and patented at MIT. Under a 2-year grant, the technology was to be transferred to the industrial lab of a small development company (PFH), where it was to be proven technically feasible ahead of additional investments toward commercialization. A major part of the effort was development of a novel approach to commercial manufacturing at full-scale (100MM vaccines per annum).

I was hired to generate the manufacturing plan. This included concept landscaping, process research and support of lab activities, concept down-selection, sub-contracted studies and process experiments, product cost modeling, and technical reporting.

Inadequacies of existing process:

•Oversized particle geometry

•Not injectable at scale

•Complex administration requirement

•Slow molding and sealing steps

•Micron-scale positioning

•Expensive manual processing

•Material waste

Product & Process Development

Feasibility, increased production, quality improvements, cost, user experience