Biocompatible 3D Printed Microneedles for Transdermal, Intradermal, and Percutaneous Applications

Microneedles (MNs) are playing an increasingly important role in biomedical applications, where minimally invasive methods are being developed that require imperceptible tissue penetration and drug delivery. To improve the integration of MNs in microelectromechanical devices, a high‐resolution 3D printing technique is implemented. A reservoir with an array of hollow MNs is produced. The flow rate through the MNs is simulated and measured experimentally. The mechanical properties of the 3D printed material, such as elasticity modulus and yield strength, are investigated as functions of printing parameters, reaching maximum values of 1750.7 and 101.8 MPa, respectively. Analytical estimation of the MN buckling, fracture, and skin penetration forces is presented. Penetration tests of MNs into a skin‐like material are conducted, where the piercing force ranges from 0.095 to 0.115 N, confirming sufficient stability of MNs. Furthermore, 200 and 400 μm‐long MN arrays are used to successfully pierce and deliver into mouse skin with an average penetration depth of 100 and 180 μm, respectively. A biocompatibility assessment is performed, showing a high viability of HCT 116 cells cultured on top of the MN's material, making the developed MNs a very attractive solution for many biomedical applications. The design and characterization of 3D printed hollow microneedles (MNs) are presented. Penetration tests into a skin‐like material are conducted, confirming sufficient stability of MNs. Furthermore, MN arrays are used to pierce and deliver into mouse skin. A complementary biocompatibility assessment indicates minimal cytotoxicity, which makes the developed MNs a desirable solution for many biomedical applications.