A novel method for producing solid polymer microneedles using laser ablated moulds in an injection moulding process

Abstract

Microneedle arrays are minimally invasive devices which offer a pain free, straightforward and efficient method for transdermal drug delivery. Manufacturing these micro-systems represents a real challenge and a mass production process with high volume outputs at low cost is lacking. In this study, we present a novel method to produce polymer microneedles using laser ablated moulds in an injection moulding process. We successfully created cone-shaped micro holes with low tip radii in a tool steel mould, using a femtosecond laser with a cross-hatching strategy. Finally, the attained mould was used in an injection moulding process to replicate polypropylene microneedles.