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Objective <p>Microneedle technologies have emerged as a promising approach to improve intradermal drug delivery. This study presents a comprehensive workflow for fabricating polymeric microneedle arrays utilising ultrahigh-resolution 3-dimensional (3D) printing and silicone mould fabrication.</p> Methods <p>In this work, an extensive toolbox with over 75 distinct microneedle designs was created and sequentially fabricated from acryl using our workflow based on ultrahigh-resolution 3D printing.</p> Results <p>The microneedle design parameters included obelisk and cone-like shapes, various lengths, base and tip diameters, and different densities. We systematically assessed the optimal design parameters for effective penetration of <i>ex vivo</i> human skin explants.</p> Conclusion <p>Our workflow, combined with application in an <i>ex vivo</i> human skin model, allows systematic comparison of multiple microneedle design parameters for efficacy. This work demonstrates the potential of this systematic modelling and ultrahigh-resolution 3D printing approach to optimize microneedles for intradermal biomedical applications, including therapeutic cancer vaccination.</p> Graphical Abstract <p></p>

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A Comprehensive Design-to-skin Pipeline to Fabricate Polymeric Microneedles Using Ultrahigh-resolution 3D Printing

  • 期刊论文

  • 出版模式：

    开放获取

  • 发表日期：

    2025年11月11日

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  • Francesco La Malfa,
  • Isabella A. van Hulst,
  • Ferry Ossendorp,
  • Urs Staufer,
  • Koen van der Maaden

摘要

Objective

Microneedle technologies have emerged as a promising approach to improve intradermal drug delivery. This study presents a comprehensive workflow for fabricating polymeric microneedle arrays utilising ultrahigh-resolution 3-dimensional (3D) printing and silicone mould fabrication.

Methods

In this work, an extensive toolbox with over 75 distinct microneedle designs was created and sequentially fabricated from acryl using our workflow based on ultrahigh-resolution 3D printing.

Results

The microneedle design parameters included obelisk and cone-like shapes, various lengths, base and tip diameters, and different densities. We systematically assessed the optimal design parameters for effective penetration of ex vivo human skin explants.

Conclusion

Our workflow, combined with application in an ex vivo human skin model, allows systematic comparison of multiple microneedle design parameters for efficacy. This work demonstrates the potential of this systematic modelling and ultrahigh-resolution 3D printing approach to optimize microneedles for intradermal biomedical applications, including therapeutic cancer vaccination.

Graphical Abstract