Free-Form Microfluidic Microneedle Array Patches

Abstract

Personalized biomedical devices, such as microneedle array patches (MAPs), represent a promising platform for transdermal drug delivery, offering a safe, minimally invasive, and user-friendly alternative to traditional hypodermic injections. However, broader adoption is constrained by limitations in payload capacity, delivery versatility, and scalable manufacturing. To address these challenges, microfluidic channel architectures are integrated with MAP technology to enable the delivery of a range of payload formats including liquids and solid-state cargos. Using injection continuous liquid interface production (iCLIP), an additive manufacturing technique capable of producing high-resolution structures, complex microfluidic MAPs are fabricated with precise and reproducible geometries. The microneedles feature a side-opening bore that reduces the risk of clogging during insertion and supports consistent transdermal fluid delivery. This platform allows for the reliable administration of multiple distinct payloads, combinational mixing, and point-of-care reconstitution of solid formulations.