Abstract
PURPOSE: Unethical attempts to misuse and overdose opioids have led to strict prescription limits, necessitating frequent hospital visits and prescriptions for long-term severe pain management. Therefore, this study aimed to develop a prototype wearable device that facilitates the extended delivery of opioid drugs while incorporating abuse-deterrent functionality, referred to as the abuse deterrent device (ADD). METHODS: The ADD was designed and fabricated using 3D-printed components, including reservoirs for the drug and contaminant, as well as an actuator. In vitro tests were conducted using a skin-mimicking layer and phosphate-buffered saline (PBS) to evaluate the drug release profile and the effectiveness of the ADD abuse-deterrent mechanism. RESULTS: Under simulated skin attachment, ADD demonstrated sustained drug release with the potential to persist for up to 200 days. Upon detachment from the skin mimic, the mechanical components of the ADD facilitated immediate exposure of the contaminant to the drug and effectively halted further drug exposure throughout-diffusion. CONCLUSION: Wearable ADD provides a secure and practical solution for the long-term treatment of high-risk medications such as opioids, enhances patient convenience, and addresses important public health concerns. SUPPLEMENTARY INFORMATION: The online version contains supplementary material available at 10.1007/s13534-025-00459-7.