A cost-effective process chain for thermoplastic microneedle manufacture combining laser micro-machining and micro-injection moulding

High-throughput manufacturing of transdermal microneedle arrays poses a significant challenge due to the high precision and number features that need be produced requirement multi-step processing methods for achieving challenging micro-features. To address this challenge, we report flexible cost-effective process chain array manufacture includes mould production using laser machining replication thermoplastic microneedles via micro-injection moulding (micromoulding). The also incorporates an in-line data monitoring capability where variability in quality can determined run captured data. Optical imaging machine vision technologies are implemented create inspection system allows rapid evaluation key indicators. work presents as method making moulds highly-suitable technique large-scale with low marginal cost.