Ian Coates

All Publications

• Tunable Applicator for Microneedle-Based Medical Devices ADVANCED MATERIALS TECHNOLOGIES Ilyn, D., Hwang, J., Coates, I. A., Dobson, J., Hung, A. H., Kamat, N. U., Tumbleston, J. R., Dulay, M. T., Jacobson, G. B., DeSimone, J. M. 2026

  View details for DOI 10.1002/admt.202502525

  View details for Web of Science ID 001687405100001

• Free-Form Microfluidic Microneedle Array Patches ADVANCED FUNCTIONAL MATERIALS Coates, I. A., Driskill, M. M., Rajesh, N. U., Lipkowitz, G., Ilyn, D., Xu, Y., Dulay, M. T., Jacobson, G. B., Tumbleston, J. R., Perry, J. L., Tian, S., DeSimone, J. M. 2025

  View details for DOI 10.1002/adfm.202514879

  View details for Web of Science ID 001565190500001

• Lyophilized SARS-CoV-2 self-amplifying RNA vaccines for microneedle Array patch delivery. Journal of controlled release : official journal of the Controlled Release Society Driskill, M. M., Coates, I. A., Hurst, P. J., Rajesh, N. U., Dulay, M. T., Waymouth, R. M., Akahata, W., Matsuda, K., Smith, J. F., Jacobson, G. B., Perry, J. L., Tian, S., DeSimone, J. M. 2025: 113944

  Abstract

  mRNA vaccines have emerged as a pivotal tool to respond to global pandemics like SARS-CoV-2. However, RNA vaccines face challenges with limited duration of immunogenicity and reliance on a special cold-chain for long term storage. Self-amplifying (saRNA) vaccines have shown sustained antigen expression and durable immune responses. Herein we developed lyophilization formulations for a SARS-CoV-2 saRNA ionizable lipid nanoparticle (LNP) to help reduce dependence on the cold chain. Our results show the induction of robust immune responses in mice by saRNA-LNPs when delivered either intramuscularly or intradermally following lyophilization and storage for up to 15 weeks at above freezing temperatures. Additionally, lyophilized saRNA-LNPs were efficiently delivered into the skin via microfluidic microarray patches (M-MAPs), inducing strong humoral and cellular immunity. M-MAPs offer a painless, self-administered alternative to traditional injections for transdermal drug delivery. Our work highlights the potential for a thermostable, self-administered RNA-LNP vaccine to improve vaccine coverage.

  View details for DOI 10.1016/j.jconrel.2025.113944

  View details for PubMedID 40499765

• High-resolution stereolithography: Negative spaces enabled by control of fluid mechanics. Proceedings of the National Academy of Sciences of the United States of America Coates, I. A., Pan, W., Saccone, M. A., Lipkowitz, G., Ilyin, D., Driskill, M. M., Dulay, M. T., Frank, C. W., Shaqfeh, E. S., DeSimone, J. M. 2024; 121 (37): e2405382121

  Abstract

  Stereolithography enables the fabrication of three-dimensional (3D) freeform structures via light-induced polymerization. However, the accumulation of ultraviolet dose within resin trapped in negative spaces, such as microfluidic channels or voids, can result in the unintended closing, referred to as overcuring, of these negative spaces. We report the use of injection continuous liquid interface production to continuously displace resin at risk of overcuring in negative spaces created in previous layers with fresh resin to mitigate the loss of Z-axis resolution. We demonstrate the ability to resolve 50-μm microchannels, breaking the historical relationship between resin properties and negative space resolution. With this approach, we fabricated proof-of-concept 3D free-form microfluidic devices with improved design freedom over device material selection and resulting properties.

  View details for DOI 10.1073/pnas.2405382121

  View details for PubMedID 39231205

• 3D-Printed Latticed Microneedle Array Patches for Tunable and Versatile Intradermal Delivery. Advanced materials (Deerfield Beach, Fla.) Rajesh, N. U., Luna Hwang, J., Xu, Y., Saccone, M. A., Hung, A. H., Hernandez, R. A., Coates, I. A., Driskill, M. M., Dulay, M. T., Jacobson, G. B., Tian, S., Perry, J. L., DeSimone, J. M. 2024: e2404606

  Abstract

  Using high-resolution 3D printing, a novel class of microneedle array patches (MAPs) is introduced, called latticed MAPs (L-MAPs). Unlike most MAPs which are composed of either solid structures or hollow needles, L-MAPs incorporate tapered struts that form hollow cells capable of trapping liquid droplets. The lattice structures can also be coated with traditional viscous coating formulations, enabling both liquid- and solid-state cargo delivery, on a single patch. Here, a library of 43 L-MAP designs is generated and in-silico modeling is used to down-select optimal geometries for further characterization. Compared to traditionally molded and solid-coated MAPs, L-MAPs can load more cargo with fewer needles per patch, enhancing cargo loading and drug delivery capabilities. Further, L-MAP cargo release kinetics into the skin can be tuned based on formulation and needle geometry. In this work, the utility of L-MAPs as a platform is demonstrated for the delivery of small molecules, mRNA lipid nanoparticles, and solid-state ovalbumin protein. In addition, the production of programmable L-MAPs is demonstrated with tunable cargo release profiles, enabled by combining needle geometries on a single patch.

  View details for DOI 10.1002/adma.202404606

  View details for PubMedID 39221508

• Growing three-dimensional objects with light. Proceedings of the National Academy of Sciences of the United States of America Lipkowitz, G., Saccone, M. A., Panzer, M. A., Coates, I. A., Hsiao, K., Ilyn, D., Kronenfeld, J. M., Tumbleston, J. R., Shaqfeh, E. S., DeSimone, J. M. 2024; 121 (28): e2303648121

  Abstract

  Vat photopolymerization (VP) additive manufacturing enables fabrication of complex 3D objects by using light to selectively cure a liquid resin. Developed in the 1980s, this technique initially had few practical applications due to limitations in print speed and final part material properties. In the four decades since the inception of VP, the field has matured substantially due to simultaneous advances in light delivery, interface design, and materials chemistry. Today, VP materials are used in a variety of practical applications and are produced at industrial scale. In this perspective, we trace the developments that enabled this printing revolution by focusing on the enabling themes of light, interfaces, and materials. We focus on these fundamentals as they relate to continuous liquid interface production (CLIP), but provide context for the broader VP field. We identify the fundamental physics of the printing process and the key breakthroughs that have enabled faster and higher-resolution printing, as well as production of better materials. We show examples of how in situ print process monitoring methods such as optical coherence tomography can drastically improve our understanding of the print process. Finally, we highlight areas of recent development such as multimaterial printing and inorganic material printing that represent the next frontiers in VP methods.

  View details for DOI 10.1073/pnas.2303648121

  View details for PubMedID 38950359

• Methods for modeling and real-time visualization of CLIP and iCLIP-based 3D printing GIANT Lipkowitz, G., Coates, I., Krishna, N., Shaqfeh, E. S. G., DeSimone, J. M. 2024; 17

  View details for DOI 10.1016/j.giant.2024.100239

  View details for Web of Science ID 001167580600001

• Printing atom-efficiently: faster fabrication of farther unsupported overhangs by fluid dynamics simulation Lipkowitz, G., Krishna, N., Coates, I., Shaqfeh, E. S. G., DeSimone, J. M. edited by Spencer, S. N. ASSOC COMPUTING MACHINERY. 2023

  View details for DOI 10.1145/3623263.3623354

  View details for Web of Science ID 001147521200011

• 3D-Printed Microarray Patches for Transdermal Applications. JACS Au Rajesh, N. U., Coates, I., Driskill, M. M., Dulay, M. T., Hsiao, K., Ilyin, D., Jacobson, G. B., Kwak, J. W., Lawrence, M., Perry, J., Shea, C. O., Tian, S., DeSimone, J. M. 2022; 2 (11): 2426-2445

  Abstract

  The intradermal (ID) space has been actively explored as a means for drug delivery and diagnostics that is minimally invasive. Microneedles or microneedle patches or microarray patches (MAPs) are comprised of a series of micrometer-sized projections that can painlessly puncture the skin and access the epidermal/dermal layer. MAPs have failed to reach their full potential because many of these platforms rely on dated lithographic manufacturing processes or molding processes that are not easily scalable and hinder innovative designs of MAP geometries that can be achieved. The DeSimone Laboratory has recently developed a high-resolution continuous liquid interface production (CLIP) 3D printing technology. This 3D printer uses light and oxygen to enable a continuous, noncontact polymerization dead zone at the build surface, allowing for rapid production of MAPs with precise and tunable geometries. Using this tool, we are now able to produce new classes of lattice MAPs (L-MAPs) and dynamic MAPs (D-MAPs) that can deliver both solid state and liquid cargos and are also capable of sampling interstitial fluid. Herein, we will explore how additive manufacturing can revolutionize MAP development and open new doors for minimally invasive drug delivery and diagnostic platforms.

  View details for DOI 10.1021/jacsau.2c00432

  View details for PubMedID 36465529

  View details for PubMedCentralID PMC9709783

• 3D-Printed Microarray Patches for Transdermal Applications JACS AU Rajesh, N. U., Coates, I., Driskill, M. M., Dulay, M. T., Hsiao, K., Ilyin, D., Jacobson, G. B., Kwak, J., Lawrence, M., Perry, J., Shea, C. O., Tian, S., DeSimone, J. M. 2022

  View details for DOI 10.1021/jacsau.2c00432

  View details for Web of Science ID 000874579200001

• Injection continuous liquid interface production of 3D objects. Science advances Lipkowitz, G., Samuelsen, T., Hsiao, K., Lee, B., Dulay, M. T., Coates, I., Lin, H., Pan, W., Toth, G., Tate, L., Shaqfeh, E. S., DeSimone, J. M. 2022; 8 (39): eabq3917

  Abstract

  In additive manufacturing, it is imperative to increase print speeds, use higher-viscosity resins, and print with multiple different resins simultaneously. To this end, we introduce a previously unexplored ultraviolet-based photopolymerization three-dimensional printing process. The method exploits a continuous liquid interface-the dead zone-mechanically fed with resin at elevated pressures through microfluidic channels dynamically created and integral to the growing part. Through this mass transport control, injection continuous liquid interface production, or iCLIP, can accelerate printing speeds to 5- to 10-fold over current methods such as CLIP, can use resins an order of magnitude more viscous than CLIP, and can readily pattern a single heterogeneous object with different resins in all Cartesian coordinates. We characterize the process parameters governing iCLIP and demonstrate use cases for rapidly printing carbon nanotube-filled composites, multimaterial features with length scales spanning several orders of magnitude, and lattices with tunable moduli and energy absorption.

  View details for DOI 10.1126/sciadv.abq3917

  View details for PubMedID 36170357