Abstract
Abstract Hot embossing was used to fabricate a microneedle array on poly(methyl methacrylate) (PMMA) substrates. Both experimental and numerical researches were carried out to investigate the whole formation process. The results showed that the edge effect would significantly influence the replication rate of final products. An optimization design of convex flow barrier was proposed to improve the replication efficiency and structure uniformity. Furthermore, optimum parameters of the flow barrier were found to be 2 mm in length and 0.2 mm in height. Reasonable high molding temperature and force were conducive to reduce the filling time and increase the average height of microneedles.
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