Comparison and Evaluation of Printing Angle Dependent Fabrication of Microneedles Using Polyjet and DLP-SLA 3D Printers

Microneedles with micron-sized needle arrays are an emerging technology for the transdermal administration of active pharmaceutical ingredients with minimally invasive pain. Over the past decade, although various additive manufacturing technologies have been employed for precise fabrication of microneedles, these methods are often limited by material compatibility and bioavailability, in addition to being time-consuming and costly. In here, we compare the resolution of Polyjet and DLP-SLA 3D printing methods for the precise fabrication of biodegradable PCLDA/PEGDA microneedles. To enhance the structural accuracy of the microneedles from both printing methods, we evaluate the 3D printing conditions, including 3D printing angle and needle height and diameter. Molds for microneedles are fabricated using optimized 3D printing methods, and subsequent replica molding processes are employed to fabricate the polymeric microneedles with sharp need tips. Finally, we use photocurable PCLDA and PEGDA for biodegradable and biocompatible microneedles, and their mechanical properties as PCLDA concentrations are analyzed to assess the strength required for skin insertion. This study has demonstrated the efficient and low-cost fabrication of high-resolution microneedles for transdermal drug delivery.