A Novel 3D-Printing-Enhanced Fabrication Method for Pattern Customizable Dissolving Microneedle Array Patches

抄録

Dissolving microneedle array patches (dMAPs) are widely used in drug delivery and cosmetic treatments for their minimally invasive nature and patient-friendly application. However, existing fabrication methods face challenges in handling short microneedles to make pattern, which are highly required in the cosmetics industry. To overcome these limitations, this study develops an improved PDMS-based micromolding enhanced by 3D printing, enabling the precise and versatile fabrication of customized microneedle arrays.Hyaluronic acid (HA) was selected as the microneedle material for its stiffness and rapid dissolution properties in human body. The proposed fabrication process involves embedding a 3D-printed block with an inner hollow pattern onto a PDMS mold. Injecting PDMS mixture into this system creates a dual-layer structure: a thin, robust PDMS layer at the base and a thicker, easily detachable PDMS layer in the hollowed areas. This approach allows for the fabrication of microneedles with customizable pattern and precise localization, irrespective of needle length.Experimental results demonstrate that this method achieves a line resolution of 0.5 lp/mm, establishing it as a reliable solution for applications requiring short and customizable pattern microneedles. These advancements pave the way for broader dMAP applications in cosmetics and medical treatments.