The invention provides for a transdermal drug delivery device for forming a drug delivery patch system comprising: a) an actuator comprising i) an outer body defining a top of the actuator, the outer body containing a cavity ii) a controller board comprising driving electronics and a battery, the controller board being positioned within the cavity and iii) an interface connection port for receiving a porator array, the interface connection port containing an anode and a cathode b) the porator array comprising: i) a top surface, with a removable adhesive attached to the top surface, the top surface containing two concentric electrical contact rings for contacting the interface connection port at the anode and the cathode upon removal of the adhesive layer ii) a bottom surface comprising a tissue interface membrane, the tissue interface membrane further comprising a substrate with at least one porator contained on or within the substrate, the bottom surface further comprising an adhesive layer for attaching the porator array to a tissue membrane and iii) an extension tab laterally and removably attached to the bottom surface, the extension tab including an adhesive applied on the bottom thereof, thereby allowing the extension tab to remain on the tissue membrane upon removal of the porator array and iv) a release liner removably attached to the bottom surface and c) a reservoir patch attached to the extension tab, the reservoir patch being applied to the microporated area of the tissue membrane after poration. The invention also provides for methods of making and methods of using the same.
