ORCID

Abstract

Polymer microneedles (MNs) have significant potential for use in transdermal delivery and diagnostics applications due to their low cost, versatility, and compatibility with medical grade materials and industrial manufacturing processes. These polymers can also have a wide range of different and desirable properties such as biocompatibility, degradability, and flexibility.To facilitate rapid development of these devices, a multifunctional manufacturing process, easily adaptable to a range of different materials and use cases, would be highly beneficial for research and prototyping purposes. With that in mind, we have developed a multifunctional platform that may be used to produce sharp-tipped microneedle arrays with a variety of substrate materials, mechanical characteristics, electrical properties, and diagnostic functionalities. The paper first presents an outline of the platform concept and the double-sided moulding process that lies at its core, followed by a description of the various add-on steps that are used to customise the geometrical, mechanical, electrical, and functional aspects of the arrays.Finally, we illustrate the versatility of the platform with three exemplars, namely a solid, electrochemically active MN sensor for biomarker diagnostics, a fabric-backed, flexible MN electrode for biopotential monitoring, and a biodegradable array for transdermal drug delivery.

Publication Date

2025-07-01

Publication Title

Sensors and Actuators A: Physical

Volume

388

ISSN

0924-4247

Acceptance Date

2025-03-17

Deposit Date

2025-03-24

Funding

This publication has emanated from research conducted with the financial support of the European Union's Horizon 2020 Research and Innovation Programme under grant #825549 (ELSAH project); the Government of Ireland through the Disruptive Technologies Innovation Fund (DT2018 0291-A, HOLISTICS); Research Ireland through the Insight Centre for Data Analytics (SFI/12/RC/2289-P2); Enterprise Ireland under the Commercialisation Fund (CF/2012/2339); the Higher Education Authority under the Programme for Research in Third-Level Institutions; and the European Regional Development Fund. Martin’s PhD was funded by 3 M. Ng’s PhD was funded by the School of Pharmacy and Pharmaceutical Sciences, Cardiff University and the Overseas Research Students Awards Scheme (ORSAS). Massufero Vergilio’s PhD internship was funded by Santander Open Academy.

Keywords

ECG electrode, Medical devices, Microneedles, Moulding, Polymer, Sensors, Transdermal drug delivery

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