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Microneedle fabrication using the plane pattern to cross-section transfer method

In this paper, microneedle fabrication using the PCT (plane pattern to cross-section transfer) method is summarized. Three types of microneedle array have been developed: the single-tip, quadruplet, and hollow microneedle arrays. A brief introduction to the fabrication process using PCT and detailed design concepts for optimizing the fabrication steps for shape improvement of the three types of microneedle are provided. The microneedle structures have controllable angled sidewalls, exhibiting an extraordinarily geometrical level of accuracy compared to what is achieved using other existing fabrication methods based on deep x-ray lithography by synchrotron radiation. Furthermore, the improvements reported in this work as compared to the results from the existing methods are: sharper tips for the single-tip microneedles, strength improvement for the quadruplet microneedles, and cost reduction for the hollow microneedles. Each type of microneedle was designed to serve a different biomedical need.