Stereolithographic Manufacture of Microneedle Patch Arrays for Blood Collection

Faraji Rad, Zahra ;   Davies, Graham ;   Anthony, Carl ;   Prewett, Philip D ;   Nordon, Robert E

3D laser lithography is used to manufacture microneedle master molds with optimal geometric designs for collection of subcutaneous capillary blood or interstitial fluid. Thermoplastic microneedles are accurately replicated at submicron resolution from the master by soft embossing. Optimal microscale designs are based on structural and fluid dynamic simulation rather than the manufacturing constraints imposed by machining or etching processes.